International Foundry Challenge Suitable Production of thin walled Aluminum Prototype and Small Series Castings for Body in White Applications

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2 2 International Foundry Challenge Suitable Production of thin walled Aluminum Prototype and Small Series Castings for Body in White Applications Joachim Gundlach, Jörg Detering

3 Contents 3 Company Information Starting Point - Requirements Integrated Casting Product and Process Development Moulding and Casting Process Competitive Factors Summary and Perspectives

4 Contents 4 Company Information

5 Locations 5 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)

6 Company Profile 6 The Grunewald Business Model is based on 4 main Business Areas. Know How Transfer and synergetic Effects create Innovations. Casting NC-Processing Aerospace Tooling and Assembly Automotive Tooling

7 Contents 7 Starting Point - Requirements

8 Body in White Concept 8 Body in White Structures contain significant portions of Castings, in order to integrate Components and to realize functional lightweight Geometries. SL-Class 17% 8% 44% 28% 3% Aluminium Castings Aluminium Metal Sheets Aluminium Profiles Steel Others Daimler AG, SL-Class: Percentage of Materials

9 Body in White Concept 9 Grunewald offers Casting Capabilities for Prototypes and Small Volume Productions. 34 Vacuum High Pressure Die Castings 2 Low Pressure Die Castings Total weight of Castings: 110kg Daimler AG, SL-Class: Castings

10 Starting Point - Requirements 10 Series Production Design and specified Mechanical Properties are realized with Low Pressure Sand Casting + Heat Treatment. Casting Geometries Daimler AG 1. High Pressure Die Casting Geometry 2. Protoype Specifiedand Wall Pre-Series Thicknesses Casting and Tolerances Productionaccording to Reference Point System (RPS) 3. Mechanical Properties equivalent to Series 4. Economical and in Time Production

11 Contents 11 Integrated Casting Product and Process Development

12 Casting Process Development 12 Specification, Properties and Quality Requirements determine the Process Development. Product Specifications Mechanical Properties Dimensional Accuracy Tolerances Surface Quality Material Properties Alloy Mould Material Black wash Gating and Feeding Technology Cooling Quality Control Process Metallurgy Crack test X-Ray Dimensional Metrology

13 CAE - Development 13 The Feasibility of thermal + mechanical Properties are analysed on basis of numerical Simulation. Boundary Conditions and Process Parameter are calculated. mechanical Properties

14 Process Tolerances Process Steps, Functions, Parameters, Tolerances and Interfaces have to be developed and defined in an integrated Process Chain to achieve Quality and Cost Effectiveness 14 Tolerances Clamping Strategy NC Joint Surfaces Orientation Timing Straightening Quality control Mechanical properties Cooling Chills Riser System Gating System Orientation Pattern Shop Pattern Material Shrinkage Joint Surfaces Joint Surfaces Product Dimensiona l tolerances RPS System Parameter T6 Orientation in Oven and Quenching Filling Opening Foundry Mould Material Cleaning Mold Stability Process Flow and Dependencies

15 Contents 15 Moulding and Casting Process Rapid Prototyping, Qualified Master Casting (QMC) Low Pressure Sand Casting

16 Foundry Areas 16 Vertical Integration leads to Reliability and Liability as well as Lead Time Reduction. CAD/CAM Simulation Modelling Rapid Prototyping Pattern Making Moulding Melting Casting Fettling Heat- Treatment NC- Processing Metrology Quality Control

17 Pattern Making 17 Specialists with Handcrafting Know How finish and complete the 5-axis machined plastic Patterns. Manual Finishing after NC-Processing

18 Mould Production 18 Black Washing and Coating Techniques create high Quality surfaces. Moulding

19 Low Pressure Sand Casting 19 Low Pressure Casting Systems produce repeatable thin walled Castings. Low Pressure Casting Technique - Crucible Volume 2 x 300 kg, Tandem System - Dynamic Pressure Control - Core Block - Sand Casting

20 Heat Treatment 20 Heat Treatment Know How to achieve specified mechanical Properties. Heat Treatment and Quenching Water and Air Accuracy +/- 1K

21 Straightening 21 Specialists with Handcrafting Know How straighten the Castings. Straightening

22 Blasting 22 Modern Blasting Technology generates regular Surfaces. Blasting Cabin

23 NC Machines (examples) 23 5-Axis Milling Technology and NC Specialists produce finished Parts x x mm 1000 x 800 x 500 mm NC finished Part Processing

24 Assembly 24 Use of Aerospace Assembly Strategies and Quality. Assembly of e. g. Helicoils and Add-On Parts

25 Pre-Series Casting 25 Daimler AG, SL Roof Component

26 Pre-Series Casting 26 Daimler AG, SL C-Pillar

27 Pre-Series Casting 27 Daimler AG, SL Crossbeam

28 Prototype Casting 28 Body In White Component

29 Contents 29 Competitive Factors

30 Know How Transfer Carbon Fibre (CFRP) into Hybrid Car Structures 30 Competitiveness per Composite Know How and Capability. Aerospace Automotive 1. CFRP Part Design 2. Production Tooling Techniques like Lay Up Tools, RTM Tools 3. Manufacturing Processes 4. NC-Processing and Water Jet Cutting (Savings in Fettling up to 75%) 5. Assembly and Adhesive Technologies

31 Know How Transfer Assembly Strategy and Technology 31 Competitiveness per Assembly Know How and Capability. Aerospace Automotive 1. DIN ISO 9100 Certification 2. Adapted Assembly Tooling Techniques 3. Process Quality Improvement 4. Qualification of Employees

32 Pattern and Tool Life Time 32 Competitiveness per professional Material Selection and Processing Know How. Material 3 Material Properties and Costs Material 1 3,- / dm3 Material 2 6,- / dm3 8,- / dm Castings Tool Life Time and Productivity Plastics Technology Casting Patterns

33 Optimization of Interfaces 33 Competitiveness per Optimization of Interfaces. CAD Milling Assembly Reference: technical Interfaces human Interfaces, communicative Competences professional Education professional communicative Behavior

34 Contents 34 Summary and Perspectives

35 Further Technical Information 35 Components: Part Dimensions: Geometrical Accuracy: Wall Dimensions: Casting Techniques: Melting Capacity: Moulding Material: Surface Finish: Surface Treatment: Tool Life Time: Production Capacity: A-, B-, C-Pillars, Window Frames, Roof Components, Joint Components, Doors, Tail Gates, others up to ca. 1500mm x 1200mm x 400mm +/- 0,8mm (Raw Part) > 2mm (+0,4mm/-0,2mm) Sand Casting, Low Pressure Sand Casting, QMC Prototype Casting on Basis of Laser sintered Rapid Prototyping Polystyrene Models or Sand printed Moulds ca. 300kg 1000kg, Prototype Volumes are possible Cold-Box Pep-Set correspondent to Moulding Material Passivation, KTL, Ni-Plating, others Plastic Tools (Material dependend, incl. Maintenance), Metal Tools x (Material dependend, incl. Maintenance) 1 - ca Castings per Year

36 Cost Effectiveness 36 Small Volumes can be produced economically with Low Pressure Sand Casting. LPSC Cost Effectiveness Complexity HPDC 1 Production No Low Pressure Sand Casting (LPSC) / High Pressure Die Casting (HPDC)

37 37 Thank you for your Attention. Grunewald GmbH & Co. KG Dr. Joachim Gundlach Biemenhorster Weg 19 D Bocholt Phone Internet