suitable production of thin walled aluminum prototype and...
TRANSCRIPT
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© Grunewald 2013© Grunewald 2013
Suitable Production of thin walled Aluminum Prototype and
Small Series Castings for Body in White Applications
Joachim Gundlach, Jörg Detering
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Contents
• Company Information
• Starting Point - Requirements
• Integrated Casting Product and Process Development
• Moulding and Casting Process
• Summary and Perspectives
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Contents
Company Information
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Grunewald
Founded 1963
Employees 225
Production Sites 6
Locations 5
Main Business Units
• Casting Production
• Tooling (Automotive, Aerospace)
• NC-Machining
• Assembly
Locations
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Casting
Automotive Tooling
NC-Processing
Aerospace Tooling and Assembly
Company Profile
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Contents
Starting Point - Requirements
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Body in White Concept
SL-Class
Aluminium Castings
Aluminium Metal Sheets
Aluminium Profiles
44%
17%
8%
28%
3%
SL-Class
Daimler AG, SL-Class: Percentage of Materials
Steel
Others
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Daimler AG, SL-Class: Castings
• 34 Vacuum High Pressure Die Castings
• 2 Low Pressure Die Castings
Total weight of Castings: 110kg
Body in White Concept
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Mercedes-Benz AMG, SLS
Body in White Concept
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Starting Point - Requirements
Protoype and Pre-Series Casting Production
1. High Pressure Die Casting Geometry2. Specified Wall Thicknesses and Tolerances according to
Reference Point System (RPS)3. Mechanical Properties equivalent to Series4. Economical and in Time Production
Casting Geometries – Daimler AG
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Contents
Integrated Casting Product and Process Development
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Product Specifications
Material Properties
Alloy
Mould Material
Black wash
Gating and Feeding Technology
Cooling
Process Metallurgy
Crack test
X-Ray
Dimensional Metrology
Mechanical Properties
Dimensional Accuracy
Tolerances
Surface Quality
Quality Control
Casting Process Development
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mechanical properties
CAE - Development
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Low Pressure Sand Casting High Pressure Die Casting
CAE - Numerical Casting Simulation
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Process Tolerances
Process Flow and Dependencies
Pattern
shop
Foundry
Heat treatment
Post processing
Machining
Dimensional
tolerances
RPS
System
Product
Mechanical
properties
Quality control
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Contents
Moulding and Casting Process• Rapid Prototyping, Qualified Master Casting (QMC)
• Low Pressure Sand Casting
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Rapid Prototyping and QMC
Selective Laser Sintering of a
Polystyrene “lost Model”
Polystyrene Model Gating + Feeding
SystemMoulding Casting
Principle of Qualified Master Casting (QMC)
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Metrology of Polystyrene Model
Rapid Prototyping and QMC
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Qualified Master Casting - QMC
Metrology of Raw Casting
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CAD-Design of the Pattern, Example C-Pillar
Pattern Design
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Pattern Making
Manual Finishing after NC-ProcessingFoto: xxx
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Mould Production
Moulding
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Low Pressure Casting Technique- Crucible Volume 300 kg Al, 2 changeable Crucibles- Dynamic Pressure Control- Core Block - Sand Casting
Low Pressure Sand Casting
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Heat Treatment and QuenchimgWater and Air
Accuracy +/- 1K
Heat Treatment
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Straightening
Straightening
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Blasting Cabin
Blasting
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1.800 x 2.100 x 1.250 mm 1000 x 800 x 500 mm
NC – Machines (examples)
NC – finished Part Processing
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Assembly of e. g. Helicoils and Add-On Parts
Assembly
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Mercedes-Benz AMG, SLS – Roof Component
Pre-Series Casting
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Pre-Series Casting
Mercedes-Benz AMG, SLS – Door Component
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Daimler AG, SL – Roof Component
Pre-Series Casting
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Pre-Series Casting
Daimler AG, SL – C-Pillar
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Daimler AG, SL – Window Frame
Pre-Series Casting
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Pre-Series Casting
Daimler AG, SL – Crossbeam
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Body In White Joint, E-Car Application
Prototype Casting
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Contents
Summary and Perspectives
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Components: A-, B-, C-Pillars, Window Frames, Roof Components, Joint Components, Doors, Tail Gates, others
Part Dimensions: up to ca. 1500mm x 1200mm x 400mm
Geometrical Accuracy: +/- 0,8mm (Raw Part)
Wall Dimensions: > 2mm (+0,4mm/-0,2mm)
Casting Techniques: Sand Casting, Low Pressure Sand Casting, QMC Prototype Casting on Basis of Laser sintered Rapid Prototyping Polystyrene Models or Sand printed Moulds
Melting Capacity: ca. 300kg – 1000kg, Prototype Volumes are possible
Moulding Material: Cold-Box, Pep-Set, Furan Resin Sand, others
Surface Finish: correspondent to Moulding Material
Surface Treatment: Passivation, KTL, Ni-Plating, others
Tool Life Time: Plastic Tools 1 – 30000 (Material dependend, incl. Maintenance), Metal Tools x – 100.000 (Material dependend, incl. Maintenance)
Production Capacity: 1 - ca. 5000 Castings per Year
Further Technical Information
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Cost Effectiveness
Co
st E
ffe
ctive
ne
ss
Production No.1 1000
LPSC
HPDC
Complexity
Low Pressure Sand Casting (LPSC) / High Pressure Die Casting (HPDC)
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Grunewald GmbH & Co. KGDr. Joachim GundlachDr. Jörg Detering
Biemenhorster Weg 19D-46395 Bocholt
Phone +49 2871 2507 151
eMail [email protected]
Internet www.grunewald.de
Thank you for your Attention.