Automobile manufacturers, particularly those in the automotive industry, are increasingly relying on die casting for structural applications. Among the most impressive vehicles on the road today are the new Jaguar I-Pace, BMW 8 Series Coupé, and Mercedes-Benz C-Class, all of which can be purchased from Jaguar. It is necessary for foundries to have the necessary skills and infrastructure in place in order to reap the benefits of this innovation in order for them to reap those benefits.
Manufacturers of automobiles have begun to incorporate shock towers and other structural components into their vehicles in recent years. Because of their adaptability, they can be used to replace a wide range of components while also reducing the overall weight of the vehicle. Aluminum die castings, as opposed to steel die casting, can assist in reducing the weight of hybrid vehicles' batteries and electric motors, which can have a positive impact on fuel economy and emissions performance. In the last five years, the size of this organization has more than doubled in size. The original equipment manufacturers (OEMs), on the other hand, believe that an additional 20% to 30% reduction is required in order to make these parts economically viable for high-volume vehicles.
Cost savings can be achieved by improving the efficiency of those aspects of the process chain that can be improved. Thinner component walls, secondary alloys, and lower heat treatment costs are just a few examples of what is possible in terms of technological advancements in the aerospace industry.
An in-depth investigation into the possibility of decreasing the thickness of the walls was carried outDespite the fact that some components have thinner walls than others, the mechanical performance of some components meets or exceeds all applicable specifications and requirements. Because of the expenditure of materials, the average component accounts for approximately 40% of the total cost of production in manufacturing. The use of thinner walls has the potential to save 10% on total project costs over the course of a project's lifecycle, according to some estimates. The same can be said for Hermann Roos, Structural Process Manager at Bühler Die Casting. Because of the reduction in wall thicknesses, die casting, die manufacturing, and downstream operations are all made more difficult to manage and control. Process fluctuations have a greater impact on the quality of the components than other factors, such as temperature, in the manufacturing process. Collaborative efforts between the automotive and foundry industries are required in order to manufacture structural parts with thinner wall thicknesses.
Recent alloy manufacturer research has revealed that secondary aluminum for structural components is a superior material choice when compared to other materials when it comes to the construction of structural components. According to Hermann Roos, the use of secondary alloys for automotive body parts is expected to increase in the near future as the industry continues to innovate. In addition to the environmental advantages, he believes that a lower overall material cost provides a significant competitive advantage over his competitors.
In this situation, it is possible to reduce or even eliminate the use of heated treatment. According to him, new alloys could be used in certain circumstances without the need for heat treatment, and he provided examples of such situations. However, automobile manufacturers continue to put these alloys to the test in a variety of applications.
There are three primary considerations in the die casting process, according to industry standards. These considerations are cycle time, uptime, and part quality. It is possible to measure the total overall efficiency of a piece of equipment (OEE) by adding up the total performance of all of the individual pieces of equipment (PPE). The term for this is overall equipment effectiveness (OEE), which is an abbreviation for overall equipment effectiveness. The process of die casting is complex, and you must first gain a thorough understanding of it before you can optimize the overall efficiency of your die casting cell. Increasing output can be accomplished by making quick adjustments to various parameters, which engineers are capable of doing. In addition, high-strength castings, such as those used in structural components, are subject to the same limitations. In order to meet their requirements, our customers require more than just high-performance facilities, as Hermann Roos explains in his presentation. Our intervention is required because of their plight. Our products and services are intended to assist you throughout the entire manufacturing process.
To determine the most appropriate die casting machine and associated equipment, as well as the most efficient production settings, we work in close collaboration with our customers. Die design, cooling and filling simulations, and other services provided by Hermann Roos are just a few of the offerings. According to Roos, diecasters can reap the benefits of services like these as well. Bühler offers a variety of courses that can be completed either in-house or on-site at their facilities, depending on your needs. Furthermore, Herr Roos believes that it is something that our customers recognize and appreciate as much as he does as a company.
Collaboration in the development of structural components, particularly for high-volume product lines, is required in order to advance the technological capabilities of the manufacturing industry. Automobile manufacturers have created a popular design known as BIW (Body in White), which is becoming increasingly popular among consumers. Hermann Roos believes that better training in the production of components for casting should be provided to designers in order to increase the use of structural components in automobiles. However, in order for die casting to be more competitive in the marketplace, it is necessary to make it more appealing to the consumer.
