Innovation by Aluminium Castings

KSM Castings Group Roadshow 2009

KSM Castings GmbH

Kloth-Senking Metallgieerei

KSM Castings GmbH

Production Sites of the KSM Castings Group

Kloth-Senking Metallgieerei, Hildesheim

KSM Castings Wernigerode GmbH, Wernigerode

Druckgusswerk Fritz Vlkel, Wuppertal

KSM Castings Dongfang, Changchun, China

DGT Druckgietechnik, Radevormwald

Turnover: Employees:

341 million Euro (FY 2009) 2,360

KSM Castings CZ a.s., Hrdek nad Nisou, Tschechien

Concordiahtte, Bendorf

Production Technologies: High Pressure Die Casting Permanent Mould Casting Counter Pressure Casting Low Pressure Casting Simultaneous Engineering System Development Quality Standards: DIN EN ISO 14001:2005

DIN EN ISO 9001:2000 DIN EN ISO/TS 16949:2002 Ford Q1

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KSM Castings Gruppe

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KSM Castings GmbH

Turnover per Customer (Fiscal Year 2009)
Total: 341 Million

2,3%, Getrag 2,1%, Ford 1,7%, Bosch 1,0 %, ZF 1,0 %, Porsche 2,4%, Mann+Hummel 2,6%, BMW 3,8%, SHW 5,2%, TRW

4,2%, Others
5,9%, China

8,3%, Audi
9,6%, Benteler

34,4%, Volkswagen

16,0%, Daimler

KSM Castings Gruppe

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KSM Castings GmbH

Production Resources

Process

Available machinery

Die Casting

95 die casting cells with locking forces of 400 to 2,700 to. 8 2 9 1 rotaries with 59 casting machines linear casting lines with 6 casting machines CPC cells tilt permanent mould casting line with 5 casting machines

Permanent mould casting

Low pressure sand casting

1 cell for prototypes and high tech products

Machining

24 automated machining lines with a total of 33 machining centres and special machines (flexible production modules) 49 CNC machining centres (milling, turning)

KSM Castings Gruppe

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KSM Castings GmbH

Topologly optimization with OptiStruct

3D-Design in virtually designed space

FE-Analysis

specification

KSM Castings
Assembling prototypes and small series

filling and solidification simulation

a Full-Service Supplier.
creation CAD-Modell finished part

Testing and verifying

Prototypes of LPDC, HPDC, CPC

System development

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KSM Castings GmbH

Expertise in Development
Calculation/Simulation

CAD Development

Process Simulation

Pro/Mechanica , CATIA-FEM MSC-Patran, MSC-Nastran HyperMesh, Optistruct Abaqus Ansys FEMFAT DADS , ADAMS Matlab / Simulink

Pro/Engineer CATIA V5 Unigraphics (IAMT)

MagmaSoft

Experimental Development Servo-hydraulic testing apparatus MTS (20 cyl. 25 kN...250 kN, Flex Test II, RPC pro) 3 Environmental chambers (-75C ... +110C, 3K/min, humidity simulation), 2 refrigerating sets Special test stands (vehicle joints: wear, leakproofness, determination of characteristics) Mobile measuring system MOPS (CESAR data systems) for field measurements - measuring and evaluation software DIA/DAGO Strain gauge measuring amplifiers (HBM-MGC, Measurement Group-System, Kistler) axle test stand (8K)

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KSM Castings GmbH

Product development / FEM calculations.
FEM calculation with Model description based on DMU description Pro/MECHANICA (in the integrated mode of ProEngineer) and CatiaV5 Nastran Abaqus Own material database

Result of calculations Load case longitudinal impact KSM Castings Gruppe Roadshow 2009 7

KSM Castings GmbH

Product development / Optimization of the topology.
Optimization of topology with Optimization with the software OptiStruct Creation of components with optimized weight Avoidance of material accumulations in unstressed ranges of the component Optimum exploitation of the used material Modelling of a smooth part in CAD that is ready to cast

optimization of topology at the example of a chassis component

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KSM Castings GmbH

System development.

Application and integration of different materials for individual parts

System development considering the design room

Assembly of prototypes and small-lot series

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KSM Castings GmbH

Generation of ideas / R&D activities
We offer a complete development and manufacturing process to you with our engineering services from design to serial production. Our product engineers, CAD engineers and die design engineers work in a team in order to represent an optimized product for the desired task with regard to costs and manufacturing processes.

Current examples for activities in light-weight construction:

Feasibility study for weight reduction of a longitudinal swinging arm. By casting a tube into a CPC part, a weight reduction of approx. 2.3 kg or 40%, respectively, can be obtained. The leading axle of the Audi A4, whose four cast nodes are supplied by KSM, is currently one of the most light-weight axles on the market. In case of a cross member, a weight reduction of more than 0.800 kg (22%) could be achieved thanks to reengineering and consideration of topology analyses and elements of bionics.
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KSM Castings GmbH

Concept for modular light-weight construction rear axle

Knuckle / longitudinal member

Sub frame side parts

Knuckle / longitudinal member

Stabilizer

Strut unit

Bottom control arm (support swinging arm)

View from front-bottom

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KSM Castings GmbH

Patent differential housing

Differential housing manufactured in CPC Process with cast on rivets to connect housing cover and housing cap.

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KSM Castings GmbH

Product portfolio
Chassis Transmission Engine peripherals Steering / Pedals

Wheel carrier

Transmission housing

Oil pump housing and cover

Pedal bracket assembly

Rear axle carrier

Slide housing

Engine brackets

Steering manifold

Front axle subframe

Piston guides

Camshaft carrier

Steering console

Knuckle KSM Castings Gruppe

Outside sheet support Roadshow 2009

Cylinder head cover

Steering housing 13

KSM Castings GmbH

Mechanical and technical features of the components

Rm Rp0,2 [N/mm2]
AlMg5Si2Mn 260 170 6 AlMg5Si2Mn 290 170 6 EN AC-AlSi10Mg 220 130 3 EN AC-AlSi9Cu3 220 120 2 Al Si11 270 180 7 Al Si11 250 150 5

Al Si9 Cu2

330 260 3

Al Si7 Mg0,3 320 260 8

A5 [%]

AlMg5Si2Mn 240 180 6

EN AC-AlSi10Mg 230 180 6 En AC-AlSi12Cu1 220 180 2

Al Si7 Mg0,6 310 260 2 RR350 300 215 3

Al Si11 Mg 210 110 15

Die Casting

Permanent Mold Casting

Low Pressure Sand Casting

Counter Pressure Casting

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KSM Castings GmbH

Chassis Components High Pressure Die Casting

Alfa Romeo Cross Member RA

Alfa Romeo Cross Member RA

Porsche Cross Member FA

VW Steering Housing

BMW Cross Member FA

Audi Pedal Assembly

Permanent Mould Casting

VW Bracket FA

BMW

Longitudinal Member FA

BMW Longitudinal Member FA

VW Subframe FA

BMW Node for Subframe FA

BMW Node for Subframe FA

Counter Pressure Casting

VW Wheel Carrier

VW Wheel Carrier

BMW Knuckle FA

Audi Knuckle

BMW Wheel Carrier RA

Tilt Permanent Mould Casting

VW Subframe FA

VW Subframe FA

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KSM Castings GmbH

Highlights after 20 years of KSMs experience in chassis components
Weldable die-casting (AlMg5Si2Mn) without premachining of the joining areas Die-casting machine: 2,700 t mould clamping force CVC-process (Controlled Vacuum Casting) One-piece subframe (920 x 420 x 200 mm) Tilt gravity die casting Completely machined

Swivel bearings with overhead control arm connections High material parameters 4-cavity counter pressure die-casting process

High material parameters without heat treatment due to use of AlMg5Si2Mn in die-casting (12 years of experience in the use of AlMg5Si2Mn in chassis components) Application in cast state without machining

3rd vehicle generation weldable gravity die casting 4-cavity production in gravity die casting

KSM Castings Gruppe

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KSM Castings GmbH

Highlights after 20 years of KSMs experience in chassis components

Cost optimization with regard to the development Replacement of the sand core by a steel slider Reduction of the construction room volume Development of a 4-cavity tool concept for gravity die casting Continuous improvement of the material values Improvement of the productions automation degree

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KSM Castings GmbH

Innovations and experience in wheel-carrying components
Mechanical properties
Yield strength: Tensile strength: Elongation: 320 N/mm 260 N/mm 8%

Possibility of designing even most complex geometries by using sliders

Complete automation of all quantity requirements, e. g. by means of a robot-conducted deburring technique Realization of even large component sizes in 4-cavity casting concepts Realization of improved component characteristics (e.g. strength) according to customer demands by using different die materials

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KSM Castings GmbH

Transmission DAG NAG Transmission Components
Components: planet wheel carrier transmission housing piston guide slider housing

GETRAG Transmission Components

Components: transmission housing clutch housing selector forks differential housing differential cover

Process: Material: Alloy:

die casting aluminum EN AC-Al Si9 Cu3 (Fe)

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KSM Castings Gruppe

KSM Castings GmbH

Transmission DAG Slider Housing
Factory: Process: Material: Alloy: Fritz Vlkel, Wuppertal Vacuum-assisted die casting aluminum Al Si9 Cu3

Special Features.
Thicknesses of wall: Drafts: Surfaces: Class of Pores : Dimensional tolerances: o At the pilot edges 0.1mm 2- 6mm 5 at the cores of sliders 1 at the lamellas blasted PK1 in valve body bores

o Positions of cores of sliders 0.8mm

o Flatness of total part 0.5mm Factory Fritz Vlkel is a development partner
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KSM Castings GmbH

Engine peripherals Porsche oil pump
Process: Material: Alloy: die casting aluminum EN AC-Al Si9 Cu3 (Fe)

Characteristics.
Sump pump consisting of 3 components
Complicated contour with many material thickenings Besides large depth (approx. 140mm) in the pump chamber contours are ready-cast due to special removal techniques. Fit drill with depth of 100mm Process-secure compliance of IT8 tolerances Pore category SHW N001 Compliance with the residual waste requirement of 5mg

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KSM Castings GmbH

Engine peripherals Oil pan for automobile
Process: Material: Alloy: die casting aluminum Al Mg5 Si2 Mn

Characteristics.
Flange hardness >HB 70 In the bottom area ductile yield >5% No heat treatment necessary Minimum machining efforts Besides their large depth, pockets can be ready-cast thanks to special removal techniques.

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KSM Castings GmbH

Engine peripherals Intake manifold
Process: Material: Alloy: pressure casting aluminum EN AC-Al Si9 Cu3 (Fe)

Characteristics
Special solution for special case: Round area is removed from the mould by means of a rotary slide valve.

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KSM Castings GmbH

Engine peripherals

Engine bracket for petrol and diesel engines

Process: Material: Alloy: die casting aluminum EN AC-Al Si9 Cu3 (Fe)

Characteristics
Optimized weight by applying topology software Ready-cast supporting and locating surfaces Conduction of an in-house durability test (pulse test) Machining on special machines 4-cavity mould

KSM test bench Sinco Tech

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KSM Castings GmbH

Innovation: Multi Tilt Casting (MTC) Bosch Pumphousing

Process: Material: Alloy: Weight:

tilt permanent mould casting Aluminium EN AC - Al Si12 Cu Ni Mg T5 1,0 to 1,6 kg

Application:

Commonrail-fuel injection pump housing Volkswagen, BMW und PSA.

Characteristics: 10-fold cast, manufactured on a rotary

Using anorganic cores to create the inside contours

5 different versions

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KSM Castings GmbH

CPC-Process flow

initial state: Mould is open Opportunity to prepare the mould

start casting process: Furnace is pressurised Melt runs up in the riser tube free from turbulences

mould filling: Mould is filled Pressure is rapidly evacuated from the chamber Max. pressure of feeding

solidification: Melt is solidifying to the central gating Pressure is disappearing Melt runs down the riser tube

removal: Mould open Casting is ejected

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KSM Castings GmbH

Innovations 3rd generation of CPC machines

automatic tooling system

faster mould-changing time faster reaction in case of surface defects quick connection of the fitting

automated melt transport

lower turbulences during the furnace filling
process the molten metal flows directly from the melting furnace into the casting furnace

optimised controlling
lower variations of pressure faster pressurisation

turnable upper mould half

improved accessibility improved maintenance to the mould Easy for the operator

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KSM Castings GmbH

Innovation: Controlled Vacuum Casting (CVC)

Process

Process: Vacuum-system: Alloy:

Size of machines: Properties

Vacuum-High Pressure Die-casting (CVC) KSM generally no restrictions serial production at the time: AlMg5Si2Mn no restrictions at KSM available size of machines: 400t 2700t

Reduction of air inclusion by mould filling Reduction of gas inclusion by lubricant and releasing agent Suitable for head treatment T4, T5, T6, T7 weldable

Possible methods of joining Welding: Welding process: Bonding: Punch riveting: suitable for body and chassis e.g. MIG, Laser, Laser-Hybrid optionally pre-treatment required depending on alloy and heat treatment

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KSM Castings GmbH

Innovation: Controlled Vacuum Casting (CVC)

Mechanical Properties Excellent mechanical properties of self-hardening alloys due to minimal porosity Improvement of strength and ductility of heat-treatable alloys due to subsequent heat treatment

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KSM Castings GmbH

Innovation: Controlled Vacuum Casting (CVC) BMW AG Die-cast subframe cross member L6
Process: Material: Alloy: Weight: Application: CVC (Controlled Vacuum Casting) Aluminium EN AC Al Mg5 Si2 Mn 7,8 kg X-DRIVE models of the BMW series L6 (5, 6 and 7 series )

Characteristics Weldable die-casting for chassis components Welding without machining is possible Mech. properties: Yield strength Rm Tensile strength Rp0,2 Elongation A5 > 270 N/mm2 > 150 N/mm2 >5%

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KSM Castings GmbH

Questions?

Suggestions?

Thank you for your attention

Contact: Sales: Sandra Hohensee +49 5121 505-4944 [email protected] Heik Lachmund +49 5121 505-474 [email protected] 31

Engineering/ project management:

KSM Castings Gruppe

Roadshow 2009