Foundry for ready-to-install aluminium and copper cast parts with in-house CNC machining in the Sauerland region of southwest Westphalia
Ohm & Häner Metallwerk GmbH & Co. KG
Olpe-Friedrichsthal (Olpe-Dahl) · DrolshagenNew on Amplifa
About Ohm & Häner
Ohm & Häner Metallwerk GmbH & Co. KG is a medium-sized, owner-managed company founded in 1961 and based in Olpe, North Rhine-Westphalia. The non-ferrous metal foundry produces ready-to-install castings from aluminium and copper casting alloys for mechanical and apparatus engineering as well as the automotive industry. Production takes place at two plants: at the main plant in Olpe-Friedrichsthal (Olpe-Dahl) with machine moulding, cold-setting hand moulding and gravity die casting, and at the aluminium sand casting plant commissioned in 2008 in Drolshagen with fully automatic HWS moulding lines. Since its foundation, the foundries have been connected to an in-house machining department with CNC turning and milling machines, so that the castings can be delivered fully machined. Among other things, the company developed the MicroSort sand reclamation system, funded by the Federal Environment Agency, for the virtually residue-free separation of moulding sand and foreign materials, and was one of the first foundries worldwide to use real-time process data to control its moulding lines.
- Site
- Olpe-Friedrichsthal
- Processes
- Sand casting (HWS moulding line, plant I), Sand casting (HWS moulding line, plant II), Machine moulding, Cold-setting hand moulding (single-part production), Gravity die casting, Turning (CNC), Milling (CNC, mill-turn centres), Ready-to-install castings / mechanical finishing
- Materials
- Aluminium casting alloys, Copper casting alloys
- Certificates
- Sensor- and camera-based process monitoring of the moulding lines
- Founded
- 1961
- Employees
- 39
- Industries
- Mechanical and apparatus engineering, Automotive industry
- 01
Pattern/mould making
- 02
Casting (sand casting, machine moulding, cold-setting hand moulding, gravity
- 03
Sand reclamation (MikroSort)
- 04
CNC turning and milling
- 05
Finishing
- 06
Delivery ready-to-install
Materials and Casting Processes
Aluminium casting alloys
Used in aluminium sand casting, machine moulding, cold-setting hand moulding and gravity die casting for mechanical engineering and the automotive industry.
Copper casting alloys
Used in sand casting, machine moulding and gravity die casting at the Olpe main plant.
Locations
Olpe-Friedrichsthal (Olpe-Dahl)
DEMain plant: foundry for copper and aluminium castings, machining
- Part weight / size
- Sand casting 0.8–100 kg; gravity die casting 0.01–60 kg
- Materials
- Aluminium and copper casting alloys
- HWS moulding line (805 × 725 × 300 mm, up to 80 moulds/h)
- 6 jolt-squeeze moulding machines (up to 1,500 × 800 mm)
- 20 vertical, horizontal and tilting die casting machines
- DMC 125 FD mill-turn centre (DMG, Duoblock)
- CNC column-type travelling machines
Drolshagen
DEPlant II: aluminium sand foundry (since 2008)
- Part weight / size
- Casting weights 0.5–60 kg
- Materials
- Aluminium casting alloys
- Fully automatic HWS moulding line (700 × 630 mm, up to 250 moulds/h)
- MikroSort sand reclamation system (Eirich, 2012)
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Sand casting (HWS moulding line, plant I)Casting | – | 805 mm × 300 mm (flask height) | 0.8 kg – 100 kg | – | Copper alloys, Aluminium alloys |
| Sand casting (HWS moulding line, plant II)Casting | – | 700 mm × 630 mm | 0.5 kg – 60 kg | – | Aluminium alloys |
| Machine mouldingCasting | – | 1,500 mm × 800 mm | – | – | Aluminium alloys, Copper alloys |
| Cold-setting hand moulding (single-part production)Casting | – | 4,000 mm × 1,500 mm | 2,000 kg | 1 | Aluminium alloys |
| Gravity die castingCasting | – | 1,200 mm × 1,200 mm | 0.01 kg – 60 kg | – | Copper alloys, Aluminium alloys |
| Turning (CNC)Machining | – | – | – | – | Aluminium alloys, Copper alloys |
| Milling (CNC, mill-turn centres)Machining | – | – | – | – | Aluminium alloys, Copper alloys |
| Ready-to-install castings / mechanical finishingAssembly | – | – | – | – | Aluminium alloys, Copper alloys |
6 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| HWS moulding line | Heinrich Wagner Sinto | 2 | Plant I: flask size 805 × 725 × 300 mm; Plant II: 700 × 630 mm | – | Olpe-Dahl (plant I), Drolshagen (plant II) |
| Jolt-squeeze moulding machine | – | 6 | up to 1,500 × 800 mm or 950 mm square | – | Olpe-Dahl |
| Tilting die casting machine / gravity die casting machine | – | 20 | Tool clamping area 500 × 300 mm to 1,200 × 1,200 mm | – | – |
| Mill-turn centre (Duoblock) | DMG (Deckel Maho) DMC 125 FD | – | – | – | Olpe-Dahl |
| CNC column-type travelling machine | – | – | – | – | – |
| MikroSort sand reclamation system | Eirich MikroSort | 1 | – | 2012 | Drolshagen |
Additional services
Quality
As part of a research project supported by the Bergakademie Freiberg, the University of Siegen and Heinrich Wagner Sinto, a control system based on real-time process data and camera technology was set up that evaluates and optimises the quality of green sand moulds directly during the moulding process.
| Evidence | Olpe-Friedrichsthal (Olpe-Dahl) | Drolshagen |
|---|---|---|
| Sensor- and camera-based process monitoring of the moulding lines |
History
- 1961
Founded by master moulder Paul Ohm and turner Alois Häner in Olpe-Friedrichsthal with ten employees.
- 1979
Workforce had grown to 39 employees by the end of the 1970s.
- 1980
Start of the strongest growth phase with a 345% revenue increase over ten years and multiple expansions of the plant.
- 1985
Addition of larger CNC-controlled column-type travelling machines.
- 2005
Expansion of machining finishing with a hall featuring a neutral energy balance (waste heat recovery, 18 geothermal probes of 100 m each); use of mill-turn centres in Duoblock design.
- 2008
Production start of the new aluminium foundry in Drolshagen on 10 September on a 70,000 m² site; one of the most modern sand foundries in Europe.
- 2010
AiF-ZIM funding for the research project on optimising foundry production processes with Bergakademie Freiberg, University of Siegen and Heinrich Wagner Sinto (€1 million volume); Best Paper Award at the eKNOW.
- 2012
Development of MikroSort sand reclamation with funding from the Federal Environment Agency, a facility unique worldwide; Dr. Ludger Ohm becomes Vice President of the VDG (until 2013).
- 2014
Prize of the IHK Siegen for the research results on Complex Event Processing systems.