Emco machines significantly reduce production times

An Austrian company that specialises in magnesium and aluminium die casting solutions for the international automotive industry, GF Casting Solutions was founded in 1972, and its facility in Altenmarkt Styria is one of 12 global production sites and employs around 650 people. The aluminium and magnesium die cast parts produced are mainly developed for the bodies, interiors and drive systems of premium cars sold worldwide; and the demands on the tools, which weigh up to 70 tonnes, are constantly increasing, with fast set-up times a key factor.

CNC turning machines from the Austrian machine tool manufacturer Emco GmbH — based in Hallein, near Salzburg — are used to manufacture the spare parts required for the die casting tools; these include a Hyperturn 65 Powermill G2 and an EmcoTurn E65 CNC turning centre, which was added last year.

Thomas Klade, a team leader at GF Casting Solutions, said: “I have been familiar with Emco machines since my training days, and both machines are perfectly tailored to our requirements and run excellently. The EmcoTurn E65 turning centre is used primarily to produce screw cores, and it has enabled us to significantly reduce its machining times.”

High demand for screw cores
He continued: “The parts are collected in a pot and unloaded via the partial conveyor belt, which also eliminates the need to open the door. We have a high demand for screw cores, and the EmcoTurn E65 has taken our internal spare parts management to the next level. Screw cores are now also produced in-house and stored for employees to use as needed.”

Highlighting features of this machine, Leopold Zenz — head of sales for Emco in Austria — said: “It is a universal turning machine with a 65mm-diameter spindle bore, counter spindle, radial turret with 12 driven tools, as well as a Y axis with 80mm stroke. For GF Casting Solutions, one of the biggest advantages of purchasing this machine is the time saved. For example, if the system is given the order to produce 15 pieces, these are produced automatically and even engraved. They are then ejected onto a conveyor belt. No further manual intervention is required, and the company has been able to reduce production time by two-thirds.”

Mr Klade concluded: “The Emco Hyperturn 65 Powermill G2, which was purchased in 2022, is also doing its job to our complete satisfaction. Thanks to this machine, we have been able to minimise and simplify the work steps — and significantly reduce the set-up and clamping times.”