CPT International 02/2019

COMPONENT DEVELOPMENT
employed. The latter point involves the
use of mold components with cooling
channels that are produced in a 3-D printing
process, and optimization of the
ejectors regarding their number, diameter
and positioning. This permitted a
15 % reduction in the average wall thickness,
which is only between 1.8 mm and
2.0 mm in large areas of the component.
Verified high-tech process chain
“A striking feature of the production
process is the complete traceability of
the entire quality history for each individual
casting,” reveals Axel Schmidt.
This starts as early as the casting cell,
where the component is laser-printed
with an individual data matrix code
after casting and deburring. This allows
allocation of all quality-relevant process
and test parameters throughout the
entire process chain right up to the
packaging and dispatch data. The code
is scanned-in before each process step
and inspected for completeness and
matching of the specifications. The next
processing step is only approved when
the computer confirms that everything
is in order so far. After the stamping
process, the components pass through
the above-mentioned T6 heat treatment
on special racks that prevent any
warpage, and are then polished and
aligned. All further transport processes
also take place in special racks, which
also carry a data matrix code. The code
of each individual casting is scanned
during insertion and allocated to the
rack. This complete traceability concept
was implemented internationally with
Audi – also in the DGS works in the
Czech Republic and China.
Robot processing cells
“Processing takes place in two completely
enclosed robot cells that are mirrored
for reasons of redundancy,” says
Heim. The components are pushed into
the cells on the racks before being individually
removed by the robot. First there
is an inspection, during which the data
matrix code is scanned-in and the correct
heat-treatment state is checked with the
help of a special eddy current process to
determine electrical conductivity. Threaded
inserts are placed in the tap holes
after mechanical processing. Whereby
appropriate inspection processes ensure
that the slugs required for screwing-in
are also reliably removed after the subsequent
breaking off. This prevents any
delay, which could cause difficulties
during subsequent processes. After completion
of the processing, the robot
A view of the fully automatic
cell for processing
the casting, including
insertion of the thread
inserts.
After the casting has
been put down, the
screen delivers all the
data for assessing component
warpage.
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