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Global trends infoundry technology and  casting production Dr.-Ing. Gotthard Wolf, German Foundry AssociationFarouk Varach...
Content:>   some statistics>   market trends>   basic expectations of our customers>   technical trends>   the South Afric...
Foundry production in the world 2009                                 -3-
Market trends for the foundry industry>   market volume>   global or regional market>   tendencies>   technical trends    ...
Specific consumption of castings to per 1 Mio. € added valueQuelle: DGV, ifo-institut                                     ...
Worldwide movement of castings consumption                                     -6-
Shipping costs and container shipping times             9 ct pro kg          Duration 30 Days     EuropaUSA               ...
Global or regional casting market?Arguments pro and contra                                Global         RegionalLogistic ...
Tendencies1.   The regional casting markets will dominate2.   In medium-term the production will follow the key market3.  ...
Growing markets for castings until 2015                            (Basis 2010)                     Germany      Europe   ...
Technical trends>   Enlargement of the added value chain    > Development partner    > Inhouse machining>   Start-optimaza...
The portion of the added value of automobile supplier              industry will arise clearly pro-rata and absolut       ...
Enlargement of added value chain                          Casting production Development performance             Enlargeme...
Basis expectations of the customer                     to the development partner: Support   in component development    ...
Basics for Function Layout and Design   Product and Function Know-how    - function of module    - integration of module ...
Start-optimazation by specific start- and quality                   management with all partners of supplier chain        ...
Importance of process planning phase                   will increase>   Time frame is getting closer>   Standards with reg...
    Process planning with traditional tools due to the compexity of pocesses and     demands on the accurancy of the plan...
Complex light weight castings                                                       (e.g. Fluid management housing)Quelle:...
Minimaziation of wall thickness     (e.g. Crankcase, grey cast iron)                                        - 20 -
Multi-material castings(steel sheet / Aluminium casting)                                    - 21 -
Energy and material efficient foundry processes      Changing the focus from         end-of-the-pipe-technologies         ...
Energy and material efficient foundry processes  (Recycling of moulding sand, dust and slag - Inside and Outside the Found...
Low emission - moulding and core sands                                                                                    ...
Low emission – moulding and core sands                                               (Cold box binder, BTX emissions)     ...
Avoiding of non added value steps in production                        (e.g. Heat treatment of cast iron)Energy consumptio...
Avoiding of non added value steps in production                   (Minimizing of fettling by avoiding fins and joint flash...
Automatisation in core shopDeburringFor automatic deburring with robots brushes ortemplates are used.Remaining burrs are r...
Automatisation in core shopAutomatic coating of cores is at the todays timestate of the art.[Source: www.robotec.de]      ...
Automatisation – Moulding PlantThe robot cell has three different stations>     Depalletizing of the cores and      turnin...
Main challenges regarding the production                      technology in foundries  Expansion of the value added chain ...
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Vortrag wolf global trends

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Vortrag wolf global trends

  1. 1. Global trends infoundry technology and casting production Dr.-Ing. Gotthard Wolf, German Foundry AssociationFarouk Varachia, Metal Casting Technology Station, SA -1-
  2. 2. Content:> some statistics> market trends> basic expectations of our customers> technical trends> the South Africa foundry industry tomorrow -2-
  3. 3. Foundry production in the world 2009 -3-
  4. 4. Market trends for the foundry industry> market volume> global or regional market> tendencies> technical trends -4-
  5. 5. Specific consumption of castings to per 1 Mio. € added valueQuelle: DGV, ifo-institut -5-
  6. 6. Worldwide movement of castings consumption -6-
  7. 7. Shipping costs and container shipping times 9 ct pro kg Duration 30 Days EuropaUSA 10 ct pro kg Indien Duration: 50 Days 11 ct pro kg Duration: 65 Days 9ct pro kg Duration: 25 Days 11 ct pro kg Duration 30 Days -7-
  8. 8. Global or regional casting market?Arguments pro and contra Global RegionalLogistic -- ++(Just in time / Shipping time / Safety of production)Quality costs - +Development partnership -- ++Cultural differences - + Wages ++ --Production costs Materials 0 0 Energy 0 0Forced local content + -(castings with high valence) -8-
  9. 9. Tendencies1. The regional casting markets will dominate2. In medium-term the production will follow the key market3. The European and American market remains but the economic growth will be in Asia4. Following the OEMs, companies build their new automotive foundries in the emerging markets.5. We will see a regional casting market but global enterprises -9-
  10. 10. Growing markets for castings until 2015 (Basis 2010) Germany Europe NAFTA / USA AsiaAutomotive ++ 0 (+) 0 ++Engineering ++ ++ - +Energy + + + ++managementConstruction - 0 0 ++industryElectronics - - - ++Ship building - 0 - 0 - 10 -
  11. 11. Technical trends> Enlargement of the added value chain > Development partner > Inhouse machining> Start-optimazation of production > reaching the Crest-line > process planning> Trend towards complex light weight castings > Complex castings > Minimization of wall thickness > multi-material-castings> Energy and material efficient foundry process> Low-emission – moulding and core sands> Avoiding of non added value steps in production > Heat treatment > minimizing of fins and fettling> Automatisation of foundry processes - 11 -
  12. 12. The portion of the added value of automobile supplier industry will arise clearly pro-rata and absolut Production automobiles (in million pieces) Supplier and Service ProviderQuelle: VDA 2004 - 12 -
  13. 13. Enlargement of added value chain Casting production Development performance Enlargement of in-house component design production depthdesign-/component calculation - machining - assembly of modules - 13 -
  14. 14. Basis expectations of the customer to the development partner: Support in component development abilitiy for data handling guaranteed component properties and costs at time of quotation (series production readiness) process and component optimazation during running serial production cooperation with service providers (special know-how) - 14 -
  15. 15. Basics for Function Layout and Design Product and Function Know-how - function of module - integration of module - design criterions - calculation of the ‘component strength‘ - 15 -
  16. 16. Start-optimazation by specific start- and quality management with all partners of supplier chain Crest-line Goal Additional production time Units = additional costs/ per day loss in turnoverQuelle: VDA 2004 Days of production - 16 -
  17. 17. Importance of process planning phase will increase> Time frame is getting closer> Standards with regard to the calculatory accurancy will rise> Components will be designed closer to the ‘limits‘, so the process frame is getting closer> Process control and compliance of assured properties in competition to alternativ production technics are demanded intensively - 17 -
  18. 18.  Process planning with traditional tools due to the compexity of pocesses and demands on the accurancy of the planning are at their limits New tool: Computer aided process-simulation > of all subprocesses in terms of production planning > of the total process in terms of sequence planning and optimazation of the total costs - 18 -
  19. 19. Complex light weight castings (e.g. Fluid management housing)Quelle: Verband der Aluminiumrecycling-Industrie e.V. (VAR) - 19 -
  20. 20. Minimaziation of wall thickness (e.g. Crankcase, grey cast iron) - 20 -
  21. 21. Multi-material castings(steel sheet / Aluminium casting) - 21 -
  22. 22. Energy and material efficient foundry processes Changing the focus from end-of-the-pipe-technologies > air cleaning with scrubbers > dumping of waste material to integrated environmental protection > low grade emission processes > minimization of process materials > energy efficiency and CO2-reduction > low emission products > reuse of recycled products - 22 -
  23. 23. Energy and material efficient foundry processes (Recycling of moulding sand, dust and slag - Inside and Outside the Foundry) Cement production Mining industry Foundryroad constructionasphalt production raw materials - 23 -
  24. 24. Low emission - moulding and core sands (No Bake Binder, BTX emissions) Benzol Toluol 7000 30000 6000 25000 5000 20000Benzol [mg/m²] Toluol [mg/m³] 4000 15000 3000 10000 2000 5000 1000 0 0 1 2 1 Serien-Furanharz-System Askuran LS-System (Neuentwicklung) Serien-Furanharz-System Askuran LS-System (Neuentwicklung) Xylol 800 700 600 500 Xylol [mg/m³] 400 300 200 100 0 1 Serien-Furanharz-System Askuran LS-System (Neuentwicklung) - 24 -
  25. 25. Low emission – moulding and core sands (Cold box binder, BTX emissions) 0,090 0,080 0,070 0,060BTX [%] 0,050 0,040 0,030 0,020 0,010 0,000 Coldbox-Biosystem Coldbox-Klassisches Coldbox-Silikatsystem Coldbox- System Lösungsm ittelfrei Fe-Bindersystem / Fe-binder system Benzol / benzene[%] Toluol / toluene [%] Xylol / xylene [%] - 25 -
  26. 26. Avoiding of non added value steps in production (e.g. Heat treatment of cast iron)Energy consumption:Melting: 550 - 800 kWh/tFerritizing/:Perlitizing 650 - 750 kWh/t Avoidable by modern process technologyStress relief No added value!heat treatment: 350 - 450 kWh/t - 26 -
  27. 27. Avoiding of non added value steps in production (Minimizing of fettling by avoiding fins and joint flash) as cast as cast too!Quelle: - 27 -
  28. 28. Automatisation in core shopDeburringFor automatic deburring with robots brushes ortemplates are used.Remaining burrs are removedwith the help of a string ofpearls, before the core isput down and broughtto moulding.[Source: www.robotec.de] - 28 -
  29. 29. Automatisation in core shopAutomatic coating of cores is at the todays timestate of the art.[Source: www.robotec.de] - 29 -
  30. 30. Automatisation – Moulding PlantThe robot cell has three different stations> Depalletizing of the cores and turning over the empty core packages> Setting cores and filters> Unpacking and suppling filters[Source: Giesserei 94 (2007) Nr. 7, Seite 70-72 ] - 30 -
  31. 31. Main challenges regarding the production technology in foundries Expansion of the value added chain by: - building of an extended development capacity - integrating machining as well as assembly capacities in the foundries Trend towards complex lightweight construction castings - Rise in number of patterns because assembly variants will disappear - Demand for individual material properties - Reduction of planning stage and start-up time - Development of production flexibility and new logistics patterns Constant refinement of production technology and production control to meet the demands ot these complex circumstances> High capital asset in automation and mechanical processing Skills and qualification of staff must grow accordingly - 31 -

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