Do LOST FOAM ADI products meet the costs of competitive parts? Forecast: "Y"

Transcription

1 Future benchmarking activities based on lost foam ADI casting Benchmarking on different levels: Technological and costs benchmarks Comparison to other processes and materials Final question to be answered: Do LOST FOAM ADI products meet the costs of competitive parts? Forecast: "Y" Y E S they do" Benchmarking - 1

2 Weight saving capabilities of Lost Foam ADI Forging ADI Sand ADI Lost Foam 11 kg (no redesign) Weight kg Machined, rolling, fatigue testing 10 kg Redesigning when τlim will be known Machined 12,8 kg 9,4 kg 8,4 kg Removed 2,2-3,2 kg 1,6 kg 1,6 kg Machining driven by 3,2 kg 1,6 kg 1,6 kg Transfer time/ total machining time 50 % Operations to be done Estimated machining cost 100 % 100 % 85% 85% * 50% + 85% * 50% * 1,6 / 3,2 = 63,75% Benchmarking - 2

3 Future benchmarking activities based on lost foam ADI casting Capability benchmark Advantages of Lost Foam ADI Feasibility benchmark Technological goals of ADISYNERGY Technological competitiveness Lost Foam ADI vs. conventional ADI / forged products Product costs of Lost Foam ADI Costs balance of product vs. production- step- costs Production costs benchmark Lost Foam ADI vs. competing products Market benchmark Market study: application capabilities of Lost Foam ADI Benchmarking - 3

4 Technological advantages of Lost Foam ADI castings - Capability benchmark - Extended degree of geometrical freedom Lost foam design of component necessary complex geometry possible Significant weight saving capabilities Product driven design Near net shape design Hollow structures of high complexity Reduced machining requirements / necessities Lower machining allowance necessary High internal complexity Reduced fettling Benchmarking - 4

5 Technological goals of ADISYNERGY - Feasibility benchmark - Premises: how to get at the advantages Optimised Process Reproducibility in all steps from design to product Basic materials meet the requirements Foam, coating, sand, alloy, Product properties Functionality due to advanced design Dimensional accuracy Mechanical properties Surface quality Production facility design Benchmarking - 5

6 Technological Competitiveness of Lost Foam ADI - Lost foam ADI compared to state of the art - Sand cast hollow ADI crankshaft vs. forged crankshaft vs. full cast ADI crankshaft Lost foam hollow ADI crankshaft vs. forged crankshaft vs. full cast ADI crankshaft vs. hollow cast ADI crankshaft vs. customers expectations (input from BIG) Benchmarking - 6

7 Product costs of Lost Foam ADI Cost type Relation to conventional technology Casting design "value- added" Casting process Fettling Machining Product performance More expensive Cheaper Cheaper Enhancement in value due to complexity and weight saving Balance: Total costs of the Lost Foam ADI casting Summary: Is the value-added content of a final product (machining, finishing, assembly ) shifted to the casting (design)? Benchmarking - 7

8 Costs balance of Lost Foam ADI vs. Competing products - Product costs benchmark - Lost foam hollow ADI product Overall product costs + "Added value" Conventional product Overall product costs (= do you get more for your money?) Lost foam ADI balanced to state of the art Benchmarking - 8

9 Application capabilities of Lost Foam ADI - Market benchmark - Market analysis: Crankshaft Camshaft Straightforward exploitation of ADISYNERGY results Benchmarking - 9