the potential of high pressure die casting for the ... · ksm castings group / the potential of...

KSM Castings Group

The potential of High Pressure Die Casting for the production of highly stressed components

in automotive applications

Dr. Klaus Greven KSM Castings Group GmbH

2 KSM Castings Group / The potential of High Pressure Die Casting for the production of highly stressed components in automotive applications

KSM Castings Group

KSM Castings

Motivation

Controlled Vacuum Casting (CVC™)

Potential Applications

Chassis

Body

Agenda


KSM Castings Group

Turnover: ~ 450 Mio. EUR

Employees: ~ 2.900

Production Technologies:

High Pressure Die Casting

Gravity Die Casting

Counter Pressure Casting

Multi-Tilt Casting

Low Pressure Sand Casting

Machining & Assembly

Development Capability:

Simultaneous Engineering

Technology Engineering

System Development

Key Figures


KSM Castings Group

1 2 3

4

5 7

Hildesheim Headquarters

High Pressure Die Casting

Gravity Die Casting


1 Wuppertal High Pressure Die Casting


2 Radevormwald High Pressure Die Casting


3 Wernigerode Gravity Die Casting


4

Hrádek nad Nisou High Pressure Die Casting


5 Changchun High Pressure Die Casting

Grtavity Die Casting


6 USA High Pressure Die Casting

Permanent Mould Casting


7

USA GERMANY CZECH REPUBLIC

CHINA

6

Global Footprint


KSM Castings Group

Front axle subframe

Cylinder head cover

Transmission housing

Steering gear box

Knuckle Pump housing

Valve body

Cross member (Variostruct)

Pillar - prototype

Pedal bracket

Product Portfolio


KSM Castings Group

KSM Castings

Motivation



Chassis

Body

Agenda


KSM Castings Group

Development of Curb Weight Example VW Golf (weight in kg)

Aluminium Content in Light Vehicles (kg aluminium per vehicle)

167153 148

132 130

95

70

90

110

130

150

170

190

Mercedes VW

Group

GM Toyota EU

Target 2012

EU

Target 2015

CO2 Fleet Emission vs. Regulatory Targets (g CO2 per km)

790890

9601,050

1,155 1,217

0

200

400

600

800

1,000

1,200

1,400

Golf I Golf II Golf III Golf IV Golf V Golf VI

+427 kg / +54%

CY

0

40

80

120

160

200

1980 1985 1990 1995 2000 2005 2010 2015 2020

Source: Roland Berger

Every OEM has the need to reduce weight

Motivation


KSM Castings Group

powertrain

60%

chassis

38%

body

2%

body

39%

chassis

24%

powertrain

16%

equipment

15%

electrical

system 6%

Typical distribution of mass Aluminum share by application

Chassis: potential for weight saving by design optimization of aluminum components

Body: potential for weight saving by substitution of steel components

Motivation


KSM Castings Group

KSM Castings

Motivation



Chassis

Body

Agenda


KSM Castings Group

Die casting tool

Heat treatment

KSM vacuum piston

Vacuum control

Process control

Main objectives

No restriction concerning process stability

No restriction concerning OEE

Welding of cast parts without surface treatment

Optimized heat treatment concerning distortion



KSM Castings Group

CVC


Heat Treatment Welding

0,0

1,0

2,0

3,0

4,0

5,0

6,0

7,0

8,0

9,0

10,0

29 30 31 32 33 34 35 36 37 38 39

po

ro

sit

y [

%]

sample


KSM Castings Group

0

50

100

150

200

250

300

0 2 4 6 8 10 12 14 16

Yie

ld S

tren

gth

[M

Pa]

Elongation [%]

Gravity Die Casting

HPDC

BIW subframes knuckles



KSM Castings Group

KSM Castings

Motivation



Chassis

Body

Agenda


KSM Castings Group

Chassis Applications

Characteristics

Product Information

Process: Controlled Vacuum Casting

Material: Aluminum

Alloy: Al Mg5 Si2 Mn

Weight: 7.82 kgs

Volume: 60,000 parts p. a.

Weldable die casting for chassis components

Weldability without any surface treatment

Mechanical properties are achieved in as cast condition

Mechanical Characteristics

Yield strength: YS >270 MPa

Tensile strength: UTS >150 MPa

Elongation: A5 >5 %

Subframe BMW 5,6,7 series 4WD


KSM Castings Group

0

2

4

6

8

10

12

14

16

020406080

100120140160180200220240260280300320

4385

4444

4553

4652

4811

4915

5109

5230

5392

5410

5464

5666

5690

5702

5775

5891

5996

6071

6117

6243

elo

ngation [

%]

UTS,

YS [

MPa]

sample

UTS YS elongation

UTS [MPa] YS [MPa] elongation [%]

Average 290.2 170.3 9.9

Standard deviation 8.8 5.7 1.8


Subframe BMW 5,6,7 series 4WD


KSM Castings Group

Design space

target: minimizing mass

boundary condition: stiffness

target: minimizing stresses

boundary condition: mass, stiffness


Rear Knuckle (load per axle ~1.000 kg)


KSM Castings Group

Cast aluminum knuckle

Redesigned CVC knuckle

Weight -22%


Series application CVC concept

Rear Knuckle (load per axle ~1.000 kg)


KSM Castings Group


Aluminum/Steel Hybrid Wheel Hub


KSM Castings Group

Fe

Al


AlSi10MnMg T6

UTS 340

YS 243

elongation 3,7

0

1

2

3

4

5

6

7

8

9

10

0

50

100

150

200

250

300

350

400

Elo

ng

ati

on

[%

]

UTS

, Y

S [

MP

a]

Aluminum/Steel Hybrid Wheel Hub


KSM Castings Group

KSM Castings

Motivation



Chassis

Body

Agenda


KSM Castings Group

ASAC (Advanced Scalable Aluminum Casting) Variants:

Body Applications


KSM Castings Group

1

2

10

7 9

6

8 5

4 3

Mass 1

4 3

6

5

2

ASAC Steel

63%

100%

Body Applications

ASAC (Advanced Scalable Aluminum Casting)


KSM Castings Group

Fmax n Fmax

maxB

critB

maxH

critH

b b Rib Rib

Cross section stabilization using ribs in the hybrid structure

Conventional Stamping assembly (B)

Hybrid structure (H)

Potential enhancements in buckling strength

Compressive stress

crit = critical buckling strength

max = maximum buckling strength

b = section profile dimension

Lightweight potential with very high structural performance

Body Applications


KSM Castings Group

• Material: Steel Stampings

• Construction: 3 piece design

• Assembly: Spot-welding, Laser- welding, Adhesive Bonding

• Material: Al/steel Hybrid

• Construction: 1 piece design

• Assembly: Hybrid Casting (Force- and Form-fit)

Body Applications


KSM Castings Group

Forc

e

Distance

3-point central bending

Test VarioStruct

Test Original117%

135%

72%

100% 100% 100%

0%

20%

40%

60%

80%

100%

120%

140%

160%

Fmax EnergyAbsorption

Weight

VarioStruct Original

Body Applications


KSM Castings Group

Weight reduction by target-oriented distribution of mass

Possible weight reduction: app. 20%

Body Applications

the potential of high pressure die casting for the ... · ksm castings group / the potential of...

Documents