In addition to the environmental aspect, the process also has economic and ergonomic benefits. The strength of the resulting light-alloy components is enhanced by the improved, faster solidification of the liquid aluminium during the casting process, as it cools from a temperature of approximately 750º C. The BMW Group is using this light-but-strong design potential as a way of producing energy-saving, fuel-efficient engines capable of higher peak cylinder pressures and increased power density.
The Landshut light-alloy foundry’s employees benefit as well, due to substantially enhanced working conditions. Until now, the casting tools had to be blasted with dry ice after every use in order to remove combustion residues. This energy-intensive process can now be dispensed with.
To accompany the introduction of inorganic sand core production, the light-alloy foundry developed new core shooting tools and equipment. The casting equipment has become less complex, since the previously required venting systems can be dispensed with. At the same time, the cooling intensity during the casting process can be increased, thus reducing manufacturing cycle times by around 10 per cent. The simulation technology used in the process and tool development was developed at the BMW Landshut plant too.
“We will be able to fully amortise the investment in tools and equipment, along with our development costs, in the space of just a few years at most thanks to increased productivity, and thanks to savings on tool maintenance, tool and workshop air extraction systems and waste air treatment systems,” says Dr Wolfgang Blümlhuber, head of the BMW light-alloy foundry. Specifically, the productivity increase works out at around 10 per cent. Tool maintenance costs will be reduced by half.
photo:BMW
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| BMW plant Landshut, light-metal foundry, cylinder head production, six-cylinder diesel engine; pouring of liquid metal during the casting process. |
The Landshut light-alloy foundry’s employees benefit as well, due to substantially enhanced working conditions. Until now, the casting tools had to be blasted with dry ice after every use in order to remove combustion residues. This energy-intensive process can now be dispensed with.
To accompany the introduction of inorganic sand core production, the light-alloy foundry developed new core shooting tools and equipment. The casting equipment has become less complex, since the previously required venting systems can be dispensed with. At the same time, the cooling intensity during the casting process can be increased, thus reducing manufacturing cycle times by around 10 per cent. The simulation technology used in the process and tool development was developed at the BMW Landshut plant too.
“We will be able to fully amortise the investment in tools and equipment, along with our development costs, in the space of just a few years at most thanks to increased productivity, and thanks to savings on tool maintenance, tool and workshop air extraction systems and waste air treatment systems,” says Dr Wolfgang Blümlhuber, head of the BMW light-alloy foundry. Specifically, the productivity increase works out at around 10 per cent. Tool maintenance costs will be reduced by half.
photo:BMW