Rapidest Prototyping: Automotive Prototype Castings with 3D Printing. Sonhar Balagopalan Key Accounts Asia Pacific

Transcription

1 Rapidest Prototyping: Automotive Prototype Castings with 3D Printing Sonhar Balagopalan Key Accounts Asia Pacific

2 Give your customers Good surprises! Lets find all bad surprises before start of production!! 2

3 Scope of Presentation How ACTech uses 3D printing and RP technologies to produce automotive castings Challenges to Produce Automotive castings using 3D printing and RP Case studies and Examples 3

4 Company Overview Foundation: Freiberg, Germany, 1995 A Materialise Group company since 2017 Personnel: approx. 380 Production area: 8500 m² Capacity: approx prototypes per year 4

5 High speed workflow 5

6 Mold Design CAD CATIA, ProE, Siemens NX, GeoMagic, 3Devolution, Creo, Magics mold design depending on customers requirements, quantity and used Rapid Prototyping techniques raw part design, adding machining allowance, design of the prepared feeding and gating system define the split lines for mold segmentation and necessary cores, cores fitted with core prints for mold assembly mold segments and cores are fitted with interlocks 6

7 Mold Design Simulation Mold filling and solidification simulation (PROCast) Prediction of possible casting defects Optimization of casting technology 7

8 Mold manufacturing SAND CASTING 3D-Furan-resin printing 3D- Cold Phenolic-resin printing Direct laser sintering Direct Mold Milling INVESTMENT CASTING Ceramic Shell Process Plaster Mold Process 8

9 Mold manufacturing Sand Casting 3D-FURAN-RESIN PRINTING Build volume: 1800 x 1000 x 700 mm Continuous manufacturing process Efficìent manufacturing of medium sized mold segments and cores 9

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11 Mold manufacturing Sand Casting 3D-Cold PHENOLIC-RESIN PRINTING (CHP) Build volume: 800 x 500 x 400 mm Fragile cores and mold segments with higher strength Manufacturing of mold parts without any post treatment 11

12 Mold manufacturing Sand Casting Laser sintering of Sand molds Build volume: 720 x 360 x 360 mm complex core packages with the accurate tolerances per piece Highest strength for complex and fragile cores 12

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14 Mold manufacturing Sand Casting Laser sintering of Sand - Unlimited Possibilities 14

15 Mold manufacturing Investment Casting Ceramic Shell Process Accelerated production of ceramic shell Due to better chilling better mechanical properties in aluminium alloys Ceramic shell is also suitable for iron, steel and nickel-base alloys Plaster Mold Process Suitable for aluminum castings Smooth surface finish 15

16 Polystyrene Pattern Investment Casting 16

17 Foundry aluminum, grey iron, ductile iron, compacted graphite iron, alloyed and high alloyed steel Special alloys following customers specification Directional solidification for better mechanical properties vacuum supported pouring technology for thin wall thicknesses 850kg melting capacity for aluminum 500 kg melting capacity for iron and steel alloys core removal with shock wave technology 17

18 Raw part treatment and testing Various heat treatment processes optical measurement vs CAD data set Tightness testing, crack detection, Fluoroscopy X-ray inspection (160kV device, radioscopy) Visual inspection and endoscopy up to 2mm diameter Ultrasonic thickness gauge Surface treatment requested by customer 18

19 CNC Machining CAM programming with Tebis and TopSolid VERICUT machining simulation Alignment with live optical measurement raw part data vs 3D-CAD-data complete offline machining setup Tool presetter with online data transfer Shuttle table systems CNC machining 5-axis simultaneous technology mill/turn and turn/mill- technology up to 1,500mm table size available 19

20 Finished part inspection In-Process measurement technology Quality testing with 3D coordinate measurement, contour and roughness measurement Tightness testing and assembly Final quality check and report 20

21 Overview of Challenges to Produce Automotive castings using 3D printing and RP Expectation is now towards Production intent Prototype castings with same quality like series manufacturing. Automotive aluminium castings are mostly designed for HPDC/LPDC process. Engine developers working on thinner wall thickness and lighter engines Experimenting with newer / variant alloys, HT 21

22 How ACTech addresses some of these issues Directional solidification for better mechanical properties (Example: Aluminum cylinder heads for turbocharged Diesel and gasoline engines.alsi10mg (heat treated) Vacuum supported pouring technology for thin wall thicknesses Conventional With Directional Sand Casting Solidification Hardness: 98 HB 5/ HB 5/250 R m : 202 Mpa 233 MPa A 5 : 2 % 5 % DAS: 62 µm 20 µm 22

23 Directional Solidification High Surface quality of machined areas near the combustion face after Directional solidification. Quality of unmachined areas and in-situ machined port areas can also be seen In-situ machining has been done after fitment of valve seats 23

24 Examples Investment casting In Cast iron, Steel and Aluminum alloys 24

25 Cylinder head with integrated exhaust collector Material: EN AC-AlSi7Mg0.3 Dimensions: 510 x 360 x 340 mm Delivery: 6 weeks including assembly machining Quantity: 2 25

26 Cylinder block Material: EN-GJL-250 Dimensions: 355 x 341 x 269 mm Delivery: first component after 7 weeks including assembly machining and honing Quantity: 5 26

27 Integral turbine housing Material: EN-GJSA-XNiSiCr Dimensions: 110 x 103 x 65 mm Delivery: 3.5 weeks including machining Quantity: 2 27

28 Compressor housing Material: EN AC-AlSi8Cu3 Dimensions: 154 x 132 x 73 mm Delivery: 3 weeks including machining Quantity: 2 28

29 Rear axle transmission Material: EN AC-AlSi7Mg0.3 T6 Dimensions: 332 x 318 x 237 mm Delivery: 4 weeks including machining Quantity: 3 29

30 V6 Crankcase Transmission Housing 30

31 Electric Race car RaceTech Formula racing team of Technical University Freiberg New role for castings in EV Integration of drivetrain and chassis. Futuristic concepts for EV Light weighting, casted frames 31

32 Electric Race car 32

33 Electric Race car 33

34 Electric Race car 34

35 Electric Race car 35

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