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© Grunewald 2015
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© Grunewald 2015
International Foundry Challenge –
Suitable Production of thin walled
Aluminum Prototype and Small Series Castings
for Body in White Applications
Joachim Gundlach, Jörg Detering
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© Grunewald 2015
Contents
• Company Information
• Starting Point - Requirements
• Integrated Casting Product and Process Development
• Moulding and Casting Process
• Summary and Perspectives
• Competitive Factors
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© Grunewald 2015
Contents
Company Information
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© Grunewald 2015
Grunewald
Founded 1963
Employees 250
Production Sites 5
Locations 5
4 main Business Units
• Casting Production (diverse Industries)
• Tooling (Automotive, Aerospace, Energy, …)
• NC-Machining (diverse Industries)
• Assembly (Automotive, Aerospace, Semiconductor)
Locations
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Casting
Automotive Tooling
NC-Processing
Aerospace Tooling and Assembly
Company Profile
The Grunewald Business Model is based on 4 main Business Areas. Know How Transfer and synergetic Effects create Innovations.
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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
Body in White Structures contain significant portions of Castings, in order to integrate Components and to realize functional lightweight Geometries.
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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
Grunewald offers Casting Capabilities for Prototypes and Small Volume Productions.
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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
Series Production Design and specified Mechanical Properties are realized with Low Pressure Sand Casting + Heat Treatment.
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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
Specification, Properties and Quality Requirements determine the Process Development.
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mechanical Properties
CAE - Development
The Feasibility of thermal + mechanical Properties are analysed on basis of numerical Simulation.Boundary Conditions and Process Parameter are calculated.
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Riser
System
Orientation
Joint
SurfacesGating
System
PatternShop
Cooling
ChillsShrinkage
Pattern
Material
Filling Foundry
Opening
Mould
Material
Mold
Stability
Cleaning
Orientation
in Oven and
Quenching
T6Parameter
Straightening
Orientation
Joint Surfaces
Timing
StrategyNC
Clamping
Joint Surfaces
Tolerances
Quality control
Process Flow and Dependencies
Process Tolerances
Dimensiona
l tolerances
RPS
System
Product
Mechanical
properties
Process Steps, Functions, Parameters, Tolerances and Interfaces have to be developedand defined in an integrated Process Chain to achieve Quality and Cost Effectiveness
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Contents
Moulding and Casting Process• Rapid Prototyping, Qualified Master Casting (QMC)
• Low Pressure Sand Casting
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Foundry Areas
CAD/CAM Simulation
Modelling
Rapid
Prototyping
Pattern
Making
Moulding Melting Casting Fettling
Heat-
Treatment
NC-
Processing
Metrology Quality Control
Vertical Integration leads to Reliability and Liability as well as Lead Time Reduction.
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Pattern Making
Manual Finishing after NC-Processing
Specialists with Handcrafting Know How finish and completethe 5-axis machined plastic Patterns.
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Mould Production
Moulding
Black Washing and Coating Techniques create high Quality surfaces.
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Low Pressure Casting Technique- Crucible Volume 2 x 300 kg, Tandem System- Dynamic Pressure Control- Core Block - Sand Casting
Low Pressure Sand Casting
Low Pressure Casting Systems produce repeatable thin walled Castings.
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Heat Treatment and QuenchingWater and Air
Accuracy +/- 1K
Heat Treatment
Heat Treatment Know How to achieve specified mechanical Properties.
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Straightening
Straightening
Specialists with Handcrafting Know How straighten the Castings.
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Blasting Cabin
Blasting
Modern Blasting Technology generates regular Surfaces.
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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
5-Axis Milling Technology and NC – Specialists produce finished Parts.
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Assembly of e. g. Helicoils and Add-On Parts
Assembly
Use of Aerospace Assembly Strategies and Quality.
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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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Pre-Series Casting
Daimler AG, SL – Crossbeam
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Body In White Component
Prototype Casting
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Contents
Competitive Factors
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Know How TransferCarbon Fibre (CFRP) into Hybrid Car Structures
Competitiveness per Composite Know How and Capability.
Aerospace Automotive
1. CFRP Part Design2. Production Tooling Techniques like Lay Up Tools, RTM Tools3. Manufacturing Processes4. NC-Processing and Water Jet Cutting (Savings in Fettling up to 75%)5. Assembly and Adhesive Technologies
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Know How TransferAssembly Strategy and Technology
Competitiveness per Assembly Know How and Capability.
Aerospace Automotive
1. DIN ISO 9100 Certification2. Adapted Assembly Tooling Techniques3. Process Quality Improvement4. Qualification of Employees
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Pattern and Tool Life Time
Mate
rial P
ropert
ies
and C
osts
Tool Life Time and Productivity
1 - 200
3,- € / dm3
Competitiveness per professional Material Selection and Processing Know How.
200 - 500 500 - 3000 Castings
6,- € / dm3
8,- € / dm3
Plastics Technology Casting Patterns
Material 1
Material 2
Material 3
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Optimization of Interfaces
Competitiveness per Optimization of Interfaces.
professional Education professional communicative Behavior
Reference: www.grunewald.de
Assembly
Milling
CAD
technical Interfaces human Interfaces, communicative Competences
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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
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
Cost E
ffectiveness
Production No.1 3000
LPSC
HPDC
Complexity
Low Pressure Sand Casting (LPSC) / High Pressure Die Casting (HPDC)
Small Volumes can be produced economically with Low Pressure Sand Casting.
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© Grunewald 2015
Grunewald GmbH & Co. KGDr. Joachim Gundlach
Biemenhorster Weg 19D-46395 Bocholt
Phone +49 2871 2507 151
eMail [email protected]
Internet www.grunewald.de
Thank you for your Attention.
