Bm wengl ceeng Lost Foam

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Lost Foam Casting Technology Process. Cermak Lostfoam Consultants

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Bm wengl ceeng Lost Foam

  1. 1. BMW´S LOST FOAM FOUNDRYWITH WIDE OPEN THROTTLE FOR THE NEW CENTURY Presented by Karel Cermak, Vulcan Engineering Co. Represented by Framewell International Ltd., Beijing
  2. 2. FOAM C´HEAD PRODUCT Cylinder Head for Engines: 2,0 l / 110 kW 2,5 l / 125 kW 2,8 l / 142 kW 3,0 l / 172 kWL/F CASTING
  3. 3. DECISION CRITERIA REDUCTION OF INNOVATIVE MACHINING STEPS COMPONENT DESIGNFLOOR SPACE REDUCTION POTENTIAL FOR FURTHER WEIGHT REDUCTIONPOSITIVE COST ADVANTAGE MODIFICATION FRIENDLY IMPROVEMENT OF ENVIRONMENT
  4. 4. PROJECT PHASES Green Light 1992 Pilot Plant 1993 First Casting 1993Technology Qualification 1995 Production Start 1998 1500 Castings per day 2000 1992 1994 1996 1998 2000 2002
  5. 5. FACTORS OF SUCCESS INTEGRATION OF ALL FOR PROJECT MANDATORY DISCIPLINES FROM VERY BEGINNING
  6. 6. FACTORS OF SUCCESS IDENTIFICATION AND CLASSIFICATION OF ALLPROCESS RELEVANT STEPS IN THE LOST FOAM
  7. 7. FACTORS OF SUCCESS TO FURNISH NECESSARY RESOURCES
  8. 8. FACTORS OF SUCCESS MANAGEMENT OF RISK AND TRUST
  9. 9. PARTNERS SELECTION VULCAN ENGINEERING AND MANUFACTURING COMPANY -THE LEADER IN REALISATION OF LOST FOAM SYSTEMS WAS INVOLVED FROM THE PILOT THROUGH TO PRODUCTION PHASE
  10. 10. Headquarters: HelenaAlabma, USAWorldwide Representation Cmplete foundry systems 150 Engineers uropean Manufactring: Leicester, UK Of 79 Lost Foam lines in the Wold, 47 built by us
  11. 11. JOB DESCRIPTIONFROM BEAD´S EXPANSION THROUGH CASTING EXTRACTION
  12. 12. THE BMW LOST FOAM FLOW
  13. 13. Raw material with blowing agentPreexpansion Steam heat appliedMoulding EPS expanded factor ca. 30 Density control criticalStabilisationGlueingCoatingDryingCluster InsertionSand FillCompactionMetal PouringExtraction
  14. 14. EPS beads filled into Al toolPreexpansion Steam heated to expand and fuseMoulding Cooled to avoid distorsion Automatic removalStabilisationGlueingCoatingDryingCluster InsertionSand FillCompactionMetal PouringExtraction
  15. 15. Controlled shrinkagePreexpansion Accelerated processingMoulding Repeatability 0,2Stabilisation 0,1 0Glueing -0,1 0 100 200 300 400Coating -0,2 With Stabilisation Oven -0,3 Without Stabilisation OvenDrying -0,4 -0,5Cluster Insertion time (mins)Sand FillCompactionMetal PouringExtraction
  16. 16. Hot melt gluePreexpansion Short “open time”Moulding Repeatability AccuracyStabilisationGlueingCoatingDryingCluster InsertionSand FillCompactionMetal PouringExtraction
  17. 17. Coating developed for lost foamPreexpansion RepeatabilityMoulding Ceramic slurry Precise viscosity/solidsStabilisationGlueingCoatingDryingCluster InsertionSand FillCompactionMetal PouringExtraction
  18. 18. Removal of all moisturePreexpansion Temperature/humidity controlledMouldingStabilisationGlueingCoatingDryingCluster InsertionSand FillCompactionMetal PouringExtraction
  19. 19. PreexpansionMouldingStabilisationGlueingCoatingDryingCluster InsertionSand FillCompactionMetal PouringExtraction
  20. 20. Dry unbonded sandPreexpansion Rain-fillMoulding Uniform Rate controllableStabilisationGlueingCoatingDryingCluster InsertionSand FillCompactionMetal PouringExtraction
  21. 21. Fluidisation - CompactionPreexpansion Precise controlMouldingStabilisationGlueingCoatingDryingCluster InsertionSand Fill Vibration Analysis 5,0 5 FFT Analysis 4Compaction 2,5 3 0,0 2Metal Pouring -2,5 1 0 -5,0 -1Extraction 0 25 50 75 100 0 25 50 75 100 ms Hz
  22. 22. EPS liquified and volatisedPreexpansion Metal replaces foamMoulding All details reproducedStabilisationGlueingCoatingDryingCluster InsertionSand FillCompactionMetal PouringExtraction
  23. 23. No shakeoutPreexpansion Sand dry and looseMoulding Sand easily recycledStabilisationGlueingCoatingDryingCluster InsertionSand FillCompactionMetal PouringExtraction
  24. 24. RESULTS CONSEQUENTIAL IN PROJECT, PROCESSMANAGEMENT&TOTAL COMMITMENT
  25. 25. RESULTS PROJECTED CAPACITY OF 1.500 CASTINGS AREPRODUCED IN 3 SHIFTS NOW
  26. 26. RESULTSOVERALL EQUIPMENT EFFECTIVENESS OEE > 0.75 ! !
  27. 27. RESULTS26 % COSTSAVINGS ! !
  28. 28. FACTS MORE THAN 400.000„LOST FOAM“ BMW´S ARE ON THE ROAD TODAY
  29. 29. FACTS VULCAN ENGINEERING´SEXPERIENCE , EXPERTISE & TOTAL SYSTEM APROACH WAS INSTRUMENTAL TO BMW SUCCESS.

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