![Page 1: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/1.jpg)
1
© Grunewald 2013© Grunewald 2013
Suitable Production of thin walled Aluminum Prototype and
Small Series Castings for Body in White Applications
Joachim Gundlach, Jörg Detering
![Page 2: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/2.jpg)
2
© Grunewald 2013
Contents
• Company Information
• Starting Point - Requirements
• Integrated Casting Product and Process Development
• Moulding and Casting Process
• Summary and Perspectives
![Page 3: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/3.jpg)
3
© Grunewald 2013
Contents
Company Information
![Page 4: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/4.jpg)
4
© Grunewald 2013
Grunewald
Founded 1963
Employees 225
Production Sites 6
Locations 5
Main Business Units
• Casting Production
• Tooling (Automotive, Aerospace)
• NC-Machining
• Assembly
Locations
![Page 5: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/5.jpg)
5
© Grunewald 2013
Casting
Automotive Tooling
NC-Processing
Aerospace Tooling and Assembly
Company Profile
![Page 6: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/6.jpg)
6
© Grunewald 2013
Contents
Starting Point - Requirements
![Page 7: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/7.jpg)
7
© Grunewald 2013
Body in White Concept
SL-Class
Aluminium Castings
Aluminium Metal Sheets
Aluminium Profiles
44%
17%
8%
28%
3%
SL-Class
Daimler AG, SL-Class: Percentage of Materials
Steel
Others
![Page 8: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/8.jpg)
8
© Grunewald 2013
Daimler AG, SL-Class: Castings
• 34 Vacuum High Pressure Die Castings
• 2 Low Pressure Die Castings
Total weight of Castings: 110kg
Body in White Concept
1
![Page 9: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/9.jpg)
9
© Grunewald 2013
1
1
2
2
3
Mercedes-Benz AMG, SLS
Body in White Concept
![Page 10: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/10.jpg)
10
© Grunewald 2013
Starting Point - Requirements
Protoype and Pre-Series Casting Production
1. High Pressure Die Casting Geometry2. Specified Wall Thicknesses and Tolerances according to
Reference Point System (RPS)3. Mechanical Properties equivalent to Series4. Economical and in Time Production
Casting Geometries – Daimler AG
![Page 11: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/11.jpg)
11
© Grunewald 2013
Contents
Integrated Casting Product and Process Development
![Page 12: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/12.jpg)
12
© Grunewald 2013
Product Specifications
Material Properties
Alloy
Mould Material
Black wash
Gating and Feeding Technology
Cooling
Process Metallurgy
Crack test
X-Ray
Dimensional Metrology
Mechanical Properties
Dimensional Accuracy
Tolerances
Surface Quality
Quality Control
Casting Process Development
![Page 13: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/13.jpg)
13
© Grunewald 2013
mechanical properties
CAE - Development
![Page 14: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/14.jpg)
14
© Grunewald 2013
Low Pressure Sand Casting High Pressure Die Casting
CAE - Numerical Casting Simulation
![Page 15: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/15.jpg)
15
© Grunewald 2013
Process Tolerances
Process Flow and Dependencies
Pattern
shop
Foundry
Heat treatment
Post processing
Machining
Dimensional
tolerances
RPS
System
Product
Mechanical
properties
Quality control
![Page 16: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/16.jpg)
16
© Grunewald 2013
Contents
Moulding and Casting Process• Rapid Prototyping, Qualified Master Casting (QMC)
• Low Pressure Sand Casting
![Page 17: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/17.jpg)
17
© Grunewald 2013
Rapid Prototyping and QMC
Selective Laser Sintering of a
Polystyrene “lost Model”
Polystyrene Model Gating + Feeding
SystemMoulding Casting
Principle of Qualified Master Casting (QMC)
![Page 18: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/18.jpg)
18
© Grunewald 2013
Metrology of Polystyrene Model
Rapid Prototyping and QMC
![Page 19: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/19.jpg)
19
© Grunewald 2013
Qualified Master Casting - QMC
Metrology of Raw Casting
![Page 20: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/20.jpg)
20
© Grunewald 2013
CAD-Design of the Pattern, Example C-Pillar
Pattern Design
![Page 21: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/21.jpg)
21
© Grunewald 2013
Pattern Making
Manual Finishing after NC-ProcessingFoto: xxx
![Page 22: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/22.jpg)
22
© Grunewald 2013
Mould Production
Moulding
![Page 23: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/23.jpg)
23
© Grunewald 2013
Low Pressure Casting Technique- Crucible Volume 300 kg Al, 2 changeable Crucibles- Dynamic Pressure Control- Core Block - Sand Casting
Low Pressure Sand Casting
![Page 24: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/24.jpg)
24
© Grunewald 2013
Heat Treatment and QuenchimgWater and Air
Accuracy +/- 1K
Heat Treatment
![Page 25: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/25.jpg)
25
© Grunewald 2013
Straightening
Straightening
![Page 26: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/26.jpg)
26
© Grunewald 2013
Blasting Cabin
Blasting
![Page 27: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/27.jpg)
27
© Grunewald 2013
1.800 x 2.100 x 1.250 mm 1000 x 800 x 500 mm
NC – Machines (examples)
NC – finished Part Processing
![Page 28: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/28.jpg)
28
© Grunewald 2013
Assembly of e. g. Helicoils and Add-On Parts
Assembly
![Page 29: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/29.jpg)
29
© Grunewald 2013
Mercedes-Benz AMG, SLS – Roof Component
Pre-Series Casting
![Page 30: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/30.jpg)
30
© Grunewald 2013
Pre-Series Casting
Mercedes-Benz AMG, SLS – Door Component
![Page 31: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/31.jpg)
31
© Grunewald 2013
Daimler AG, SL – Roof Component
Pre-Series Casting
![Page 32: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/32.jpg)
32
© Grunewald 2013
Pre-Series Casting
Daimler AG, SL – C-Pillar
![Page 33: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/33.jpg)
33
© Grunewald 2013
Daimler AG, SL – Window Frame
Pre-Series Casting
![Page 34: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/34.jpg)
34
© Grunewald 2013
Pre-Series Casting
Daimler AG, SL – Crossbeam
![Page 35: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/35.jpg)
35
© Grunewald 2013
Body In White Joint, E-Car Application
Prototype Casting
![Page 36: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/36.jpg)
36
© Grunewald 2013
Contents
Summary and Perspectives
![Page 37: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/37.jpg)
37
© Grunewald 2013
Components: A-, B-, C-Pillars, Window Frames, Roof Components, Joint Components, Doors, Tail Gates, others
Part Dimensions: up to ca. 1500mm x 1200mm x 400mm
Geometrical Accuracy: +/- 0,8mm (Raw Part)
Wall Dimensions: > 2mm (+0,4mm/-0,2mm)
Casting Techniques: Sand Casting, Low Pressure Sand Casting, QMC Prototype Casting on Basis of Laser sintered Rapid Prototyping Polystyrene Models or Sand printed Moulds
Melting Capacity: ca. 300kg – 1000kg, Prototype Volumes are possible
Moulding Material: Cold-Box, Pep-Set, Furan Resin Sand, others
Surface Finish: correspondent to Moulding Material
Surface Treatment: Passivation, KTL, Ni-Plating, others
Tool Life Time: Plastic Tools 1 – 30000 (Material dependend, incl. Maintenance), Metal Tools x – 100.000 (Material dependend, incl. Maintenance)
Production Capacity: 1 - ca. 5000 Castings per Year
Further Technical Information
![Page 38: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/38.jpg)
38
© Grunewald 2013
Cost Effectiveness
Co
st E
ffe
ctive
ne
ss
Production No.1 1000
LPSC
HPDC
Complexity
Low Pressure Sand Casting (LPSC) / High Pressure Die Casting (HPDC)
![Page 39: Suitable Production of thin walled Aluminum Prototype and ...files.messe.de/abstracts/51604_121100_Gundlach_Grunewald1.pdf · Grunewald GmbH & Co. KG Dr. Joachim Gundlach Dr. Jörg](https://reader033.vdocuments.mx/reader033/viewer/2022053001/5f05b7207e708231d414575e/html5/thumbnails/39.jpg)
39
© Grunewald 2013
Grunewald GmbH & Co. KGDr. Joachim GundlachDr. Jörg Detering
Biemenhorster Weg 19D-46395 Bocholt
Phone +49 2871 2507 151
eMail [email protected]
Internet www.grunewald.de
Thank you for your Attention.