innovation by aluminium castings, ksm.pdf

8/14/2019 Innovation by Aluminium Castings, KSM.pdf

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KSM Castings GmbHKloth-Senking Metallgieerei

KSM Castings Group

Roadshow 2009Innovation by Aluminium Castings


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KSMCastings GmbH

2KSM Castings Gruppe Roadshow 2009

Kloth-Senking Metallgieerei,Hildesheim

Druckgusswerk Fritz Vlkel,Wuppertal

DGT Druckgietechnik,Radevormwald

Concordiahtte,Bendorf

KSM Castings Wernigerode GmbH,Wernigerode

KSM Castings CZ a.s.,Hrdek nad Nisou, Tschechien

KSM Castings Dongfang,Changchun, China

Production Sites of the KSM Castings Group

Turnover:

Employees:

Production Technologies:

Quality Standards:

341 million Euro (FY 2009)

2,360

High Pressure Die CastingPermanent Mould CastingCounter Pressure CastingLow Pressure CastingSimultaneous EngineeringSystem Development

DIN EN ISO 14001:2005DIN EN ISO 9001:2000DIN EN ISO/TS 16949:2002Ford Q1


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KSMCastings GmbH


Total: 341 Million

2,6%, BMW1,7%, Bosch

1,0 %, ZF

5,9%, China9,6%, Benteler

16,0%, Daimler34,4%, Volkswagen

2,1%, Ford

2,3%, Getrag2,4%, Mann+Hummel

3,8%, SHW

8,3%, Audi

5,2%, TRW

4,2%, Others

1,0 %, Porsche

Turnover per Customer (Fiscal Year 2009)


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KSMCastings GmbH


Process Available machinery

Die Casting

Permanent mould casting

95 die casting cells with locking forces of 400 to 2,700 to.

Low pressure sand casting

Machining

24 automated machining lines with a total of33 machining centres and special machines(flexible production modules)

49 CNC machining centres (milling, turning)

8 rotaries with 59 casting machines

2 linear casting lines with 6 casting machines

9 CPC cells

1 tilt permanent mould casting line with 5 casting machines

1 cell for prototypes and high tech products

Production Resources


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KSMCastings GmbH


specification

3D-Design in virtuallydesigned space

Topologly optimizationwith OptiStruct FE-Analysis

filling and solidificationsimulation

creation CAD-Modellfinished part

System developmentPrototypes of LPDC, HPDC, CPC

Testing and verifying

Assembling prototypes

and small series

KSM Castings

a Full-Service Supplier.


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KSMCastings GmbH


Calculation/Simulation

Pro/Mechanica , CATIA-FEM

MSC-Patran, MSC-Nastran

HyperMesh, Optistruct

Abaqus

Ansys

FEMFAT

DADS , ADAMS

Matlab/ Simulink

CAD Development

Pro/Engineer CATIA V5

Unigraphics (IAMT)

Experimental Development

Servo-hydraulic testing apparatus MTS (20 cyl. 25 kN...250 kN, Flex Test II, RPC pro)

3 Environmental chambers (-75C ... +110C, 3K/min, humidity simulation), 2 refrigerating sets

Special test stands (vehicle joints: wear, leakproofness, determination of characteristics)

Mobile measuring system MOPS (CESAR data systems) for field measurements

DIA/DAGO - measuring and evaluation software

Strain gauge measuring amplifiers (HBM-MGC, Measurement Group-System, Kistler)

axle test stand (8K)

Process Simulation

MagmaSoft

Expertise in Development


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KSMCastings GmbH


FEM calculation with

Model description based on DMU description

Pro/MECHANICA (in the integrated mode of

ProEngineer) and CatiaV5

Nastran Abaqus

Own material database

Result of calculations

Load case longitudinal impact

Product development / FEM calculations.


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KSMCastings GmbH


Optimization of topology with

Optimization with the software OptiStruct

Creation of components with optimized weight

Avoidance of material accumulations in

unstressed ranges of the component

Optimum exploitation of the used material

Modelling of a smooth part in CAD that is ready to cast

optimization of topology at the example of a chassis component

Product development / Optimization of the topology.


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KSMCastings GmbH


System development consideringthe design room

Assembly of prototypesand small-lot series

Application and integration of differentmaterials for individual parts

System development.


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KSMCastings GmbH


Current examples for activities in light-weight construction:

Feasibility study for weight reduction of a longitudinalswinging arm.By casting a tube into a CPC part, a weight reduction ofapprox. 2.3 kg or 40%, respectively, can be obtained.

The leading axle of the Audi A4, whose four cast nodes aresupplied by KSM, is currently one of the most light-weightaxles on the market.

In case of a cross member, a weight reduction of more than0.800 kg (22%) could be achieved thanks to reengineeringand consideration of topology analyses and elements ofbionics.

We offer a complete development and manufacturing process to you

with our engineering services from design to serial production. Ourproduct engineers, CAD engineers and die design engineers work in ateam in order to represent an optimized product for the desired taskwith regard to costs and manufacturing processes.

Generation of ideas / R&D activities


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KSMCastings GmbH


View from front-bottom

Concept for modular light-weight construction rear axle

Knuckle /longitudinal

memberSub frame side parts

Strut unit

Stabilizer

Knuckle /longitudinal

member

Bottom control arm(support swinging

arm)


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KSMCastings GmbH


Patent differential housing

Differential housing manufacturedin CPC Process with cast on rivetsto connect housing cover andhousing cap.


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KSMCastings GmbH


Chassis Transmission Engine peripherals Steering / Pedals

Wheel carrier

Rear axle carrier

Front axle subframe

Transmission housing

Slide housing

Piston guides

Oil pump housing and cover

Engine brackets

Pedal bracket assembly

Steering manifold

Steering consoleCamshaft carrier

Knuckle Outside sheet support Cylinder head cover

Product portfolio

Steering housing


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KSMCastings GmbH


RmRp0,2

[N/mm2]

A5[%]

270180

7

Al Si11

250150

5

Al Si11

Counter PressureCasting

21011015

Al Si11 Mg

PermanentMold Casting

240

1806

AlMg5Si2Mn

290170

6

AlMg5Si2Mn

230180

6

EN AC-AlSi10Mg

220130

3

EN AC-AlSi10Mg

En AC-AlSi12Cu1220

1802

EN AC-AlSi9Cu3220120

2

AlMg5Si2Mn

260170

6

RR350

300215

3

Al Si7 Mg0,6310260

2

Al Si9 Cu2330260

3

Al Si7 Mg0,3

320260

8

Low PressureSand Casting

Die Casting

Mechanical and technical features of the components


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KSMCastings GmbH


Alfa RomeoCross Member RA

High Pressure Die Casting

Alfa RomeoCross Member RA

BMWLongitudinal Member FA

VWBracket FA

Tilt Permanent Mould Casting

VWWheel Carrier

PorscheCross Member FA

BMWLongitudinal Member FA

VWSubframe FA

Permanent Mould Casting

Counter Pressure Casting

VWSubframe FA

BMWCross Member FA

VWSteering Housing

AudiPedal Assembly

BMWNode for Subframe FA

VWWheel Carrier

BMWKnuckle FA

VWSubframe FA

Audi

Knuckle BMWWheel Carrier RA

BMWNode for Subframe FA

Chassis Components
http://ksm-inside/KSMCastings/ZB/Vertrieb/Teilebilder/Forms/DispForm.aspx?ID=139&RootFolder=/KSMCastings/ZB/Vertrieb/Teilebilder/Teilebilderhttp://ksm-inside/KSMCastings/ZB/Vertrieb/Teilebilder/Forms/DispForm.aspx?ID=141&RootFolder=/KSMCastings/ZB/Vertrieb/Teilebilder/Teilebilder


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KSMCastings GmbH


Highlights after 20 years of KSMs experience in chassis components

Weldable die-casting (AlMg5Si2Mn) without premachining of the

joining areas Die-casting machine: 2,700 t mould clamping force CVC-process (Controlled Vacuum Casting)

One-piece subframe (920 x 420 x 200 mm) Tilt gravity die casting Completely machined

Swivel bearings with overhead control arm connections High material parameters 4-cavity counter pressure die-casting process

High material parameters without heat treatment due to use of AlMg5Si2Mnin die-casting (12 years of experience in the use of AlMg5Si2Mn in chassis

components) Application in cast state without machining

3rd vehicle generation weldable gravity die casting 4-cavity production in gravity die casting


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KSMCastings GmbH


Highlights after 20 years of KSMs experience in chassis components

Cost optimization with regard to the development

Replacement of the sand core by a steel slider

Reduction of the construction room volume

Development of a 4-cavity tool concept for gravity die casting

Continuous improvement of the material values

Improvement of the productions automation degree


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KSMCastings GmbH


Innovations and experience in wheel-carrying components

Mechanical properties

Yield strength: 320 N/mm Tensile strength: 260 N/mm Elongation: 8 %

Possibility of designing even most complex geometries by using sliders

Complete automation of all quantity requirements, e. g. by means of a robot-conducteddeburring technique

Realization of even large component sizes in 4-cavity casting concepts

Realization of improved component characteristics (e.g. strength) according to customerdemands by using different die materials


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KSMCastings GmbH


Transmission

Components: planet wheel carriertransmission housing

piston guide

slider housing

DAG NAG Transmission Components

Components: transmission housingclutch housingselector forksdifferential housingdifferential cover

GETRAG Transmission Components

Process: die casting

Material: aluminum

Alloy: EN AC-Al Si9 Cu3 (Fe)


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KSMCastings GmbH


Transmission

DAG Slider Housing

Factory: Fritz Vlkel, Wuppertal

Process: Vacuum-assisted die casting

Material: aluminum

Alloy: Al Si9 Cu3

Special Features.

Thicknesses of wall: 2- 6mm

Drafts: 5 at the cores of sliders

1 at the lamellas

Surfaces: blasted

Class of Pores : PK1 in valve body bores

Dimensional tolerances:

o At the pilot edges 0.1mm

o Positions of cores of sliders 0.8mm

o Flatness of total part 0.5mm

Factory Fritz Vlkel is a development partner
http://ksm-inside/KSMCastings/ZB/Vertrieb/Teilebilder/Teilebilder/11372%20CVT%20Ventilgehaeuse.jpg


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KSMCastings GmbH


Porsche oil pump

Process: die casting

Material: aluminum

Alloy: EN AC-Al Si9 Cu3 (Fe)

Engine peripherals

Characteristics.

Sump pump consisting of 3 components

Complicated contour with many materialthickenings

Besides large depth (approx. 140mm) in thepump chambercontours are ready-cast due to special removaltechniques.

Fit drill with depth of 100mm

Process-secure compliance of IT8 tolerances

Pore category SHW N001

Compliance with the residual waste requirementof 5mg

KSM C ti G bH


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KSMCastings GmbH


Oil pan for automobile

Process: die castingMaterial: aluminumAlloy: Al Mg5 Si2 Mn

Characteristics.

Flange hardness >HB 70

In the bottom area ductile yield >5%

No heat treatment necessary

Minimum machining efforts

Besides their large depth, pockets can be ready-cast

thanks to special removal techniques.

Engine peripherals

KSM C ti G bH


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KSMCastings GmbH


Intake manifold

Process: pressure castingMaterial: aluminumAlloy: EN AC-Al Si9 Cu3 (Fe)

Engine peripherals

Characteristics

Special solution for special case:

Round area is removed from the mould by means

of a rotary slide valve.

KSM Castings GmbH


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KSMCastings GmbH


Engine bracket for petrol and diesel engines

Process: die castingMaterial: aluminumAlloy: EN AC-Al Si9 Cu3 (Fe)

Characteristics

Optimized weight by applying topology software

Ready-cast supporting and locating surfaces

Conduction of an in-house durability test (pulse test)

Machining on special machines

4-cavity mould

Engine peripherals

KSM test benchSinco Tech

KSM Castings GmbH


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KSMCastings GmbH


Process: tilt permanent mould casting

Material: Aluminium

Alloy: EN AC - Al Si12 Cu Ni Mg T5

Weight: 1,0 to 1,6 kg

Application: Commonrail-fuel injection pump housingVolkswagen, BMW und PSA.

Characteristics:

10-fold cast, manufactured on a rotary

Using anorganic cores to create the inside contours 5 different versions

Innovation: Multi Tilt Casting (MTC)

Bosch Pumphousing

KSM Castings GmbH


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KSMCastings GmbH


CPC-Process flow

initial state:

Mould is openOpportunity toprepare the mould

start castingprocess:

Furnace ispressurised

Melt runs up in theriser tube free fromturbulences

solidification:

Melt is solidifying tothe central gatingPressure is

disappearingMelt runs down theriser tube

mould filling:

Mould is filledPressure is rapidlyevacuated from the

chamberMax. pressure offeeding

removal:

Mould openCasting is ejected

KSM Castings GmbH


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KSMCastings GmbH


Innovations 3rd generation of CPC machines

automatic tooling system faster mould-changing time

faster reaction in case of surface defects

quick connection of the fitting

automated melt transport

lower turbulences during the furnace filling

process the molten metal flows directly from the

melting furnace into the casting furnace

optimised controlling

lower variations of pressure

faster pressurisation

turnable upper mould half

improved accessibility

improved maintenance to the mould

Easy for the operator

KSM Castings GmbH


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KSMCastings GmbH


Innovation: Controlled Vacuum Casting (CVC)

Process

Process: Vacuum-High Pressure Die-casting (CVC)Vacuum-system: KSMAlloy: generally no restrictions

serial production at the time: AlMg5Si2MnSize of machines: no restrictions

at KSM available size of machines: 400t 2700t

Properties

Reduction of air inclusion by mould filling Reduction of gas inclusion by lubricant and releasing agent Suitable for head treatment T4, T5, T6, T7 weldable

Possible methods of joining

Welding: suitable for body and chassisWelding process: e.g. MIG, Laser, Laser-HybridBonding: optionally pre-treatment requiredPunch riveting: depending on alloy and heat treatment

KSM Castings GmbH


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KSMCastings GmbH



Mechanical Properties

Excellent mechanical properties of self-hardening alloys due to minimal porosity

Improvement of strength and ductility of heat-treatable alloys due to subsequent heat treatment

KSM Castings GmbH


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KSMCastings GmbH


BMW AGDie-cast subframe cross member L6

Process: CVC (Controlled Vacuum Casting)

Material: Aluminium

Alloy: EN AC Al Mg5 Si2 Mn

Weight: 7,8 kgApplication: X-DRIVE models of the BMW series L6

(5, 6 and 7 series )

Characteristics

Weldable die-casting for chassis components

Welding without machining is possible

Mech. properties: Yield strength Rm > 270 N/mm2Tensile strength Rp0,2 > 150 N/mm

2

Elongation A5 > 5 %


KSM Castings GmbH


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KSMCastings GmbH


Questions?

Suggestions?

Thank you for yourattention

Contact:

Sales: Sandra Hohensee+49 5121 [email protected]

Engineering/ Heik Lachmundproject management: +49 5121 505-474

[email protected]

innovation by aluminium castings, ksm.pdf

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