Product- and process development

FROM GREAT IDEAS TO REAL PRODUCTS

Business activities

• revision of existing design
• new product- and technology development
• support the design department
• introduction of series production
• Reverse Engineering

Advantages

• minimal period of development
• interlocking of component part construction and mold assembly
• relieving the customer’s engineers for their operational development
   
• minimal development costs
• testing of a close-to-production prototype
   
• minimal manufacturing costs
• mergence of technology and function
   
• rapid start of production
• know-how transfer to the series production foundry

Examples for product development

Hydraulic manifold
Requirement:	internal pressure 300 bar, 5 g acceleration with attached parts as a load
Solution:	design suitable for casting selection of material according to the FEM-calculation lay out the design for the casting system production- / casting simulation
Result / the customer’s benefit:	rapid start of production no modification during start of series production low production costs (due to a two-part mold with two cores, machined in two clampings)

Immersion for stirring device
Requirement:	stirring device for extreme operating conditions (high wear resistance required) the machinability of the hub is to be guaranteed
Solution:	composite construction: gravity die casting pouring of the blades into the hub

Crank case of a Chrysler Imperial Custom Eight   (Reverse Engineering)
Requirement:	exclusively individual manufacturing true to the original casting on strict confidentiality
Solution:	generation of a 3D-CAD-model of the component part by 3-D measurement, computer tomography and subsequent secondary construction mold design pouring, testing, CNC machining -> finished part
Result / the customer’s benefit:	replica of the component part true to the original guaranteed quality by high manufacturing- and testing standards the re-use of know-how and equipment enables the manufacturing of a certain amount of cost saving parts

Examples for process development

Composite casting braking disc
Advantages:	saving the process step of mold assembly with a higher solidity of the component part at the same time lightweight construction on unsprung masses improved full force during life cycle, wear reduction “life cycle- brake disk“ transformed steel plate pot (further saving of dimensions)
Requirements:	development of a manufacturing technology- iron composite material heat treatment technology for the establishing of a interstage structure
Solution:	identification of casting relevant parameter development and checking of different flux material development and checking of different composite technologies test the testing facility marketing of the development
Result / the customer’s benefit:	save weight while keeping constant costs improve comfort a higher resistance against wear

Thin wall steel casting
Challenge:	-substitution of a large surface welded construction
Development / Results:	identification of material suitable for thin wall castings special design of the ingate-system realization of a smaller wall thickness (2,5 mm) for larger areas avoid cracks and dunting high ductility- and consistency value

Example: Under-carriage cross beam
Material	duplex steel Nitronic 19D
Dimension	1.000 x 180 x 220 mm
Weight	11,4 kg
Mechanical properties	tensile strength:  720MPa 0,2%-elastic limit:  460MPa breaking elongation: 43%

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