Giga-casting / Méga-casting
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 boring tool
PCD boring tool
- Form E cut for burr reduction
2. FaceMill-Diamond-ES
FaceMill-Diamond-ES
- Short machining time
- Highest flexibility due to modularity
- Brazed PCD blades for long tool lives
3. PCD bore milling tool
PCD bore milling tool
- Drilling and milling in one tool
4. MEGA-Drill-Alu
MEGA-Drill-Alu
- Uncoated or coated
- Pre-cutting stage for reduction of burr formation
5. MEGA-180°-Drill-Alu
MEGA-180°-Drill-Alu
- Uncoated or coated
- Spot drilling on inclined surfaces
6. OptiMill-Alu-HPC-Pocket
OptiMill-Alu-HPC-Pocket
- Drilling and milling with one tool