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.
Structural component for Gigacasting manufacturing technology

Key Machining Tools

  1. PCD boring tool
  2. FaceMill-Diamond-ES
  3. PCD bore milling tool
  4. MEGA-Drill-Alu
  5. MEGA-180°-Drill-Alu
  6. OptiMill-Alu-HPC-Pocket

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. Ferramenta para mandrilamento PCD

PCD boring tool for component machining in gigacastin/megacasting

Ferramenta para mandrilamento PCD
  • Forma corte E para redução de rebarbas

2. FaceMill-Diamond-ES

FaceMill-Diamond-ES milling cutter for component machining in gigacasting/megacasting

FaceMill-Diamond-ES

  • A mais alta flexibilidade através da modularidade
  • Arestas de corte PCD soldadas para uma longa vida
  • Tempo de usinagem curto

3. Ferramenta para fresamento do furo de PCD

PCD bore milling tool for component machining in gigacasting/megacasting

Ferramenta para Fresamento do furo de PCD

  • Furação e fresamento em uma única ferramenta

4. MEGA-Drill-Alu

MEGA-Drill-Alu drilling tool for component machining in gigacasting/megacasting

MEGA-Drill-Alu

  • Sem ou com revestimento
  • Passos de pré-corte para a redução da formação de rebarbas

5. MEGA-180°-Drill-Alu

MEGA-180°-Drill-Alu drilling tool for component machining in gigacasting/megacasting

MEGA-180°-Drill-Alu

  • Sem ou com revestimento
  • Início do furo em superfícies inclinadas

6. OptiMill-Alu-HPC-Pocket

OptiMill-Alu-HPC-Pocket drilling tool for component machining in gigacasting/megacasting

OptiMill-Alu-HPC-Pocket

  • Furação e fresamento com apenas uma ferramenta