BMW´S LOST FOAM BMW´S LOST FOAM FOUNDRY FOUNDRY

WITH WIDE OPEN WITH WIDE OPEN THROTTLE THROTTLE

FOR THE NEW CENTURYFOR THE NEW CENTURY Presented by

Karel Cermak, Vulcan Engineering Co.Represented by Framewell International Ltd., Beijing

L/F CASTING

FOAM C´HEAD PRODUCT

2,0 l / 110 kW

2,5 l / 125 kW

2,8 l / 142 kW

3,0 l / 172 kW

Cylinder Head for Engines:

DECISION CRITERIADECISION CRITERIAREDUCTION OF

MACHINING STEPS

IMPROVEMENT OF ENVIRONMENT

POSITIVE COST ADVANTAGE

FLOOR SPACE REDUCTION

MODIFICATION FRIENDLY

POTENTIAL FOR FURTHER WEIGHT

REDUCTION

INNOVATIVE COMPONENT

DESIGN

PROJECT PHASES

2000

1998

1995

1993

1993

1992

1992 1994 1996 1998 2000 2002

1500 Castings per day

Production Start

Technology Qualification

First Casting

Pilot Plant

Green Light

INTEGRATION OF ALL INTEGRATION OF ALL

FOR PROJECT FOR PROJECT

MANDATORY DISCIPLINES MANDATORY DISCIPLINES

FROM VERY BEGINNINGFROM VERY BEGINNING

FACTORS OF SUCCESS

IDENTIFICATION AND IDENTIFICATION AND

CLASSIFICATION OF ALL CLASSIFICATION OF ALL

PROCESS RELEVANT STEPS PROCESS RELEVANT STEPS

IN THE LOST FOAMIN THE LOST FOAM

FACTORS OF SUCCESS

TO FURNISH NECESSARYTO FURNISH NECESSARY

RESOURCESRESOURCES

FACTORS OF SUCCESS

MANAGEMENT MANAGEMENT

OF RISK OF RISK

AND TRUSTAND TRUST

FACTORS OF SUCCESS

VULCAN ENGINEERING AND VULCAN ENGINEERING AND

MANUFACTURING COMPANY - MANUFACTURING COMPANY -

THE LEADER IN REALISATION OF THE LEADER IN REALISATION OF

LOST FOAM SYSTEMS WAS LOST FOAM SYSTEMS WAS

INVOLVED FROM THE PILOT INVOLVED FROM THE PILOT

THROUGH TO PRODUCTION THROUGH TO PRODUCTION

PHASEPHASE

PARTNERS SELECTION

Headquarters: HelenaAlabma, USA

uropean Manufactring: Leicester, UK

Worldwide Representation

150 Engineers

Of 79 Lost Foam lines in the Wold, 47 built by us

Cmplete foundry systems

FROM BEAD´S EXPANSIONFROM BEAD´S EXPANSIONTHROUGHTHROUGH

CASTING EXTRACTIONCASTING EXTRACTION

JOB DESCRIPTION

THE BMW LOST FOAM FLOWTHE BMW LOST FOAM FLOW

Preexpansion

Moulding

Stabilisation

Glueing

Coating

Drying

Cluster Insertion

Sand Fill

Compaction

Metal Pouring

Extraction

Raw material with blowing agentSteam heat appliedEPS expanded factor ca. 30Density control critical

Preexpansion

Moulding

Stabilisation

Glueing

Coating

Drying

Cluster Insertion

Sand Fill

Compaction

Metal Pouring

Extraction

EPS beads filled into Al toolSteam heated to expand and fuseCooled to avoid distorsionAutomatic removal

-0,5

-0,4

-0,3

-0,2

-0,1

0

0,1

0,2

0 100 200 300 400

Preexpansion

Moulding

Stabilisation

Glueing

Coating

Drying

Cluster Insertion

Sand Fill

Compaction

Metal Pouring

Extraction

Controlled shrinkageAccelerated processingRepeatability

time (mins)

With Stabilisation OvenWithout Stabilisation Oven

Preexpansion

Moulding

Stabilisation

Glueing

Coating

Drying

Cluster Insertion

Sand Fill

Compaction

Metal Pouring

Extraction

Hot melt glueShort “open time”RepeatabilityAccuracy

Preexpansion

Moulding

Stabilisation

Glueing

Coating

Drying

Cluster Insertion

Sand Fill

Compaction

Metal Pouring

Extraction

Coating developed for lost foamRepeatabilityCeramic slurryPrecise viscosity/solids

Preexpansion

Moulding

Stabilisation

Glueing

Coating

Drying

Cluster Insertion

Sand Fill

Compaction

Metal Pouring

Extraction

Removal of all moistureTemperature/humidity controlled

Preexpansion

Moulding

Stabilisation

Glueing

Coating

Drying

Cluster Insertion

Sand Fill

Compaction

Metal Pouring

Extraction

Preexpansion

Moulding

Stabilisation

Glueing

Coating

Drying

Cluster Insertion

Sand Fill

Compaction

Metal Pouring

Extraction

Dry unbonded sandRain-fillUniformRate controllable

Preexpansion

Moulding

Stabilisation

Glueing

Coating

Drying

Cluster Insertion

Sand Fill

Compaction

Metal Pouring

Extraction

Fluidisation - CompactionPrecise control

ms0 25 50 75 100

5,0

2,5

0,0

-2,5

-5,0

Hz0 25 50 75 100

5

4

3

2

1

0

-1

Vibration Analysis FFT Analysis

Preexpansion

Moulding

Stabilisation

Glueing

Coating

Drying

Cluster Insertion

Sand Fill

Compaction

Metal Pouring

Extraction

EPS liquified and volatisedMetal replaces foamAll details reproduced

Preexpansion

Moulding

Stabilisation

Glueing

Coating

Drying

Cluster Insertion

Sand Fill

Compaction

Metal Pouring

Extraction

No shakeoutSand dry and looseSand easily recycled

CONSEQUENTIAL IN PROJECT, PROCESS

MANAGEMENT&TOTALCOMMITMENT

RESULTS

PROJECTED CAPACITY OF 1.500 CASTINGS ARE

PRODUCED IN 3 SHIFTS NOW

RESULTS

OVERALL EQUIPMENT EFFECTIVENESS

OEE > 0.75 ! !

RESULTS

26 % COST SAVINGS ! !

RESULTS

MORE THAN 400.000

„LOST FOAM“ BMW´S ARE ON THE ROAD TODAY

FACTS

VULCAN ENGINEERING´SEXPERIENCE , EXPERTISE & TOTAL SYSTEM APROACH WAS INSTRUMENTAL TO

BMW SUCCESS.

FACTS