Gigacasting / megacasting
New manufacturing technologies such as giga- and megacasting are revolutionising the automotive
industry. Instead of multiple individual parts, complex structural components are now
produced in a single casting. Aluminium alloys are used to manufacture components that are
bigger, more lightweight, yet resilient. These processes promise to reduce weight, boost performance
and help ensure safety in future vehicles.
industry. Instead of multiple individual parts, complex structural components are now
produced in a single casting. Aluminium alloys are used to manufacture components that are
bigger, more lightweight, yet resilient. These processes promise to reduce weight, boost performance
and help ensure safety in future vehicles.
Features and Machining Requirements
- Wall thickness between 2 and 5 mm
- Newly developed aluminium alloy for improved flow characteristics
- Large component dimensions (L=160 cm x B=160 cm x H=130 cm)
- Defined surfaces for adhesive surfaces
- Diameter tolerance ±0.05 mm or 5±50 μm
- Deep machining contours
- Low-burr drilling without cover formation at the bore outlet
- Low-burr milling
- Production of various bore diameters
- Increased non-productive time and longer travel distances between different machining steps
- Low cutting pressure leads to deformation of component
- Vibration-prone due to long projection lengths
- Lubrication through MQL and aluminium alloy
1. PCDボーリングツール
PCDボーリングツール
- バリ低減のためのEタイプの切れ刃形状
2. フェイスミル・ダイヤモンドES
フェイスミル・ダイヤモンドES
- モジュール化による最大の汎用性
- 長寿命を実現するロウ付けPCDの切れ刃
- 短い加工時間
3. PCDドリルミーリングツール
PCDドリルミーリングツール
- 1つのツールによるドリルとミーリング加工
4. MEGA-Drill-Alu
MEGA-Drill-Alu
- ノンコーティングあるいはコーティング仕 様が可能
- バリの発生を抑える刃先形状
5. MEGA-180°-Drill-Alu
MEGA-180°-Drill-Alu
- ノンコーティングあるいはコーティング仕 様が可能
- 傾斜面へのスポットドリル
6. OptiMill-Alu-HPC-Pocket
OptiMill-Alu-HPC-Pocket
- 1つのツールによるドリルとミーリング 加工