As an automotive supplier, the
Hirschvogel Group manufactures around 15,000 to 20,000 parts per day — over three million annually. Fully automated series production is essential, with optimised cycle times and maximum process reliability being top priorities. However, by utilising the simulation and optimisation software Vericut, machining processes can be analysed and optimised for series production in advance — with remarkable benefits.
Founded in 1938 as a village blacksmith in Denklingen, the Hirschvogel Group has a long proud history, and fast forward to 2025, the company has evolved into one of the world’s largest automotive suppliers in the field of hot and cold forging of steel and aluminium, as well as the subsequent machining — its customers include all major automotive manufacturers and suppliers worldwide. The company produces a wide range of components and assemblies for drivetrains, transmissions, chassis, bodywork, fuel systems, combustion engines, and electric motors. Most cars around the world will contain at least one component made by Hirschvogel.
A clear trend is always present. Peter Zotz, responsible for machining process development and with Hirschvogel’s Schongau plant for 15 years in various departments, explained: “The components we develop are constantly becoming lighter, while also needing to withstand high loads.”
Weight-optimised componentsHirschvogel brings a wealth of experience and innovation when it comes to highly stressed, weight-optimised components. From forged parts to ready-to-install components, the family-owned company based in Denklingen (Bavaria) provides everything from a single source. Mr Zotz continued: “We are a development partner and manufacturing specialist for the automotive industry. Besides forging, machining plays a major role in production.”
As a cost-sensitive supplier dealing with high volumes, every cent and every second counts. “That is why we have been using Vericut since 2013. It allows us to identify errors and optimise our manufacturing processes before actual machining even starts.”
At Hirschvogel, all machining programs are written manually as NC code using an editor. Philipp Berchtold, responsible for programming at the Schongau site, explained that this unconventional approach is because “it is the fastest process for our needs”. As components are becoming lighter and more complex and must be delivered ready for installation, challenges in machining are increasing. To verify and optimise these programs, Hirschvogel relies on Vericut sotware.
Because each part is optimised as much as possible, Hirschvogel uses a wide range of control types and machine tools. He added: “Vericut is completely independent of control systems, and we can test and optimise our parameterised programs at our desks before a single chip is cut.”
Since 1988, Vericut has been considered an ideal tool for simulating, verifying, and optimising CNC machining. Dirk Weiß, responsible for sales in Germany and Austria at Vericut, said: “For the user, it is the safest way to simulate real machining using a virtual machine.” The simulation software is, as mentioned, entirely independent of the control system, CAM software (if used), and CNC machine.
Detailed process analysisHirschvogel’s product development process is divided into phases. In the quotation phase, space analysis of the production system is the focus. Mr Berchtold said: “Here, critical tools, clamping devices, loading/unloading, and turret swing-outs are checked.” This is followed by a feasibility study, which involves a detailed process analysis, including tools and manufacturing quality.
Once the system concept is finalised, the process development phase begins. Mr Berchtold continued: “Each machine or control uses its own defined program structures consisting of up to 150 subprograms, illustrating the complexity.” Depending on the situation, existing program structures may be reused or must be newly created or adapted.
In the third phase, the component’s suitability for series production is reviewed by the responsible department and in-house automation technicians. After final approval, Vericut is used for collision checks and process optimisation. Mr Berchtold said: “We focus on smooth production flow with no downtime to avoid any delays during actual machining, and all of this happens before the part even reaches the machine.” The simulation takes only a few minutes. Mr Weiß explained: “If an error is found, you can fix it and continue simulating from that point.”
The programming department at Hirschvogel creates a data package for each part for use in series production. It includes the program structure, the programs themselves, a reviewer file (for feedback from production colleagues), and a machine setup sheet. Mr Berchtold, pleased with the results, said: “This data package speeds up setup and program adjustments, which leads to significant cost savings.”
Thanks to the process reliability provided by Vericut, Hirschvogel can optimise machining of forged steel and aluminium parts for the automotive industry before production begins. Mr Berchtold added: “We are currently testing additional feed rate optimisations using the Vericut Force module, which we expect will yield another productivity boost.” Force is a physics-based optimisation method that determines the maximum safe feed rate for a given cutting condition based on cutting force, spindle power, and maximum chip thickness.
Together with Vericut, Hirschvogel is also working on achieving even more detailed cycle time analyses. Mr Weiß concluded: “At Vericut we are aiming to reduce theoretical cycle time deviation to under 1%.”