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. Outil d'alésage PCD

PCD boring tool for component machining in gigacastin/megacasting

Outil d'alésage PCD
  • Forme E pour la réduction des bavures

2. FaceMill-Diamond-ES

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

FaceMill-Diamond-ES

  • Flexibilité maximale basée sur la modularité
  • Arêtes de coupe PCD brasées pour une durée de vie élevée
  • Temps d'usinage plus rapide

3. Outil de perçage et de fraisage en PCD

PCD bore milling tool for component machining in gigacasting/megacasting

Outil de perçage et de fraisage en PCD

  • Perçage et fraisage combinés dans un seul outil

4. MEGA-Drill-Alu

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

MEGA-Drill-Alu

  • Revêtue ou non revêtue
  • Étape de pré-découpe pour réduire la formation de bavures

5. MEGA-180°-Drill-Alu

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

MEGA-180°-Drill-Alu

  • Revêtue ou non revêtue
  • Centrage sur des surfaces inclinées

6. OptiMill-Alu-HPC-Pocket

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

OptiMill-Alu-HPC-Pocket

  • Perçage et fraisage en un seul outil