“MACHINING OF DIE CASTING DIES”

UDDEHOLM AUTOMOTIVE TOOLING SEMINAR

FEBRUARY 9-11,2005

BORJA GARCIA
 SEMINAR TARGETS

1.- INTRODUCE AURRENAK

2.- INTRODUCE DIE CASTING TOOLING MANUFACTURING

 AGENDA
1.-AURRENAK:
• OUR MISSION

• BACKGROUND & PRODUCTS

• FOUNDRY GROUP WITH LORAMENDI

2.-TOOLING MANUFACTURING, “Q C D TARGET”:

• CUSTOMER ORIENTED ORGANISATION

• FROM DRAWING TO ENGINEERING

• MANUFACTURING CORE PROCESS CAVITIES

• FIRST TRIALS INHOUSE & CORRECTIONS

• MANUFACTURING IMPROVEMENTS
 AGENDA
1.-AURRENAK:
• OUR MISSION

• BACKGROUND & PRODUCTS

• FOUNDRY GROUP WITH LORAMENDI

2.-TOOLING MANUFACTURING, “Q C D TARGET”:

• CUSTOMER ORIENTED ORGANISATION

• FROM DRAWING TO ENGINEERING

• MANUFACTURING CORE PROCESS CAVITIES

• FIRST TRIALS INHOUSE & CORRECTIONS

• MANUFACTURING IMPROVEMENTS
 OUR MISSION
“TO OFFER TO OUR CUSTOMERS SOLUTIONS FOR THEIR NEEDS ON
DEVELOPING CASTINGS & TOOLINGS”

WE WANT TO BE RECOGNISED BY :

– OUR CUSTOMER ORIENTATION

– THE HIGH QUALITY OF OUR PRODUCT & SERVICES
– OUR COMPROMISE WITH RESULTS

OUR RESPONSABILITY IS TO GET :

– HIGH INTERNATIONAL POSITION

– EXCELLENT COMPETITIVENESS
– HEALTHY FINNANCIAL POSITION
– TO BE ABLE TO OFFER COMPLETE SOLUTIONS TO OUR CUSTOMER
 BACKGROUND
• Established in 1974
• 5000 m2 builded
• Located in VITORIA-GASTEIZ
• 100% Automotive industry
• ISO 9001 since 1996
• Foundry Group with LORAMENDI 2004
 SALES , INVESTMENT & PEOPLE
18
16
14 109
110 108
12
108
10
8 106
104
6
104 102
4 102
2 102
0 100
2000 2001 2002 2003 2004
98
SALES (MILL €) 2000 2001 2002 2003 2004
4,5 ASSOCIATES
4 ENGINEERING
3,5
3 QUALITY
2,5 22 FINANCIAL
2
DEPT.
1,5 7
COMMERCIAL
1
60 4
0,5 6 PURCHASING
0
5
PRODUCTION
1995 1997 1999 2001 2002 2003 2004
INVESTMENTS (MILL €)
 PRODUCTS

CAST IRON HIGH PRESSURE ALUMINIUM DIES

TOOLING DIES

PATTERN DIES LOW PRESSURE GRAVITY

PLATES

CORE-BOXES
TRIMMING DIES DIES
PRESS TOOLING
ASSEMBLY FIXTURES
DIMENSIONAL CORE BOXES CORE BOXES
CHECKING FIXTURES

LEAK TESTING DIE CASTING

EQUIPMENT MACHINES
GREY IRON L4 CYL.BLOCK
GREY IRON V8 CYL. BLOCK
HIGH PRESSURE 4L CYL. BLOCK
HIGH PRESSURE AUTOM.
TRANSMISSION
HIGH PRESSURE MANUAL
TRANSMISSION
Mg HIGH PRESSURE BODY PART
LOW PRESSURE V8 CYL. BLOCK
LOW PRESSURE V8 CYL. BLOCK
LOW PRESSURE CYL. HEAD
GRAVITY CYL. HEAD
 REFERENCES

TUPY BEIQI FUTIAN

 PRODUCTS

MOULDING ALUMINUM CASTING CORE MAKING

LINES MACHINES FACILITIES

VERTICAL AUTOMATIC LINES SINGLE MACHINES

FLASKLESS M/C

HORIZONTAL
MACHINES
FOUNDRY GROUP TURN-KEY PROJECTS
SALES & SERVICE
NETWORK
 AGENDA
1.-AURRENAK:
• OUR MISSION

• BACKGROUND & PRODUCTS

• FOUNDRY GROUP WITH LORAMENDI

2.-TOOLING MANUFACTURING, “Q C D TARGET”:

• CUSTOMER ORIENTED ORGANISATION

• FROM DRAWING TO ENGINEERING

• MANUFACTURING CORE PROCESS CAVITIES

• FIRST TRIALS INHOUSE & CORRECTIONS

• MANUFACTURING IMPROVEMENTS
 QUALITY, COST ,DELIVERY TARGETS

• FIRST TOOLING, “DEVELOPMENT”

– COST DOWN PRESSURE EUROPE MARKET

– INCREASING PERFORMANCE
– INCREASING QUALITY
– LATE KICK OFF & SHORT DELIVERY
– STRONG TECHNICAL SUPPORT

• REPEAT TOOLING, “PRODUCTION”

CHINA, INDIAN, ... MARKETS
– LOW COST TOOLING
 CUSTOMER ORIENTED ORGANISATION
CUSTOMER TEAM

Project Technical Assembly

Design team Assembly Trials
Manager Manager Team
Quality

SUPPORT
SUPPORT PROCESSES
PROCESSES
Financial, Human Purchasing
Resources & Outsourcing
Management and
Information
Technologies Quality

Iron and Sand Gravity/Low High pressure

moulding pressure Die Die casting
Casting
Manufacturing

ORDER-DELIVERY-SERVICE PROCESS MANAGEMENT

 AGENDA
1.-AURRENAK:
• OUR MISSION

• BACKGROUND & PRODUCTS

• FOUNDRY GROUP WITH LORAMENDI

2.-TOOLING MANUFACTURING, “Q C D TARGET”:

• CUSTOMER ORIENTED ORGANISATION

• FROM DRAWING TO ENGINEERING

• MANUFACTURING CORE PROCESS CAVITIES

• FIRST TRIALS INHOUSE & CORRECTIONS

• MANUFACTURING IMPROVEMENTS
 FROM DRAWING TO ENGINEERING
CATIA V4, CATIA V5,
UNIGRAPHICS, PRO-E,
I-DEAS,...

FROM DWG 2D TO
SOLID 3D
 FROM DRAWING TO ENGINEERING

FROM SOLID TO
MANUFACTURING DWG
 FROM DRAWING TO ENGINEERING

3D

2D
FROM DRAWING TO ENGINEERING
FILLING SIMULATION
FROM DRAWING TO ENGINEERING
SOLIDIFICATION SIMULATION
 FROM DRAWING TO ENGINEERING
DIE HOLDERS STRESS ANALYSIS

CRITICAL AREAS
EVALUATION
 AGENDA
1.-AURRENAK:
• OUR MISSION

• BACKGROUND & PRODUCTS

• FOUNDRY GROUP WITH LORAMENDI

2.-TOOLING MANUFACTURING, “Q C D TARGET”:

• CUSTOMER ORIENTED ORGANISATION

• FROM DRAWING TO ENGINEERING

• MANUFACTURING CORE PROCESS CAVITIES

• FIRST TRIALS INHOUSE & CORRECTIONS

• MANUFACTURING IMPROVEMENTS
TOOLING MANUFACTURING
CAVITIES ROUGHING

BOTH CNC & CAD/CAM

ROUGHING BEFORE HEAT
TREATMENT (HRC 42-44)
TOOLING MANUFACTURING
CAVITIES FINISHING

CAD/CAM CASTING
SHAPE FINISHING AFTER
HEAT TREAMENT
 TOOLING MANUFACTURING
CAVITIES FINISHING

BY EDM

& FINAL CNC MACHINING

 TOOLING MANUFACTURING
CMM INSPECTION

•CMM DEA MACHINES

•SW’S :METROLOG, SILMA , PC-DEMIS
 TOOLING MANUFACTURING
BOLSTERS & ANCILLARY OUTSIDE MACHINING

•ROUGHING
•STRESS RELIEF
•FINISHING
•INSPECTION
TOOLING MANUFACTURING
PRE-ASSEMBLY
& SPOTTING CAVITIES
TOOLING MANUFACTURING
FINAL ASSEMBLY
 AGENDA
1.-AURRENAK:
• OUR MISSION

• BACKGROUND & PRODUCTS

• FOUNDRY GROUP WITH LORAMENDI

2.-TOOLING MANUFACTURING, “Q C D TARGET”:

• CUSTOMER ORIENTED ORGANISATION

• FROM DRAWING TO ENGINEERING

• MANUFACTURING CORE PROCESS CAVITIES

• FIRST TRIALS INHOUSE & CORRECTIONS

• MANUFACTURING IMPROVEMENTS
 FIRST TRIALS INHOUSE
HIGH PRESSURE

2.000 TN LOCKING FORCE MACHINE

 FIRST TRIALS INHOUSE
CORE SAND MANUFACTURING
FIRST TRIALS INHOUSE
CORES INSPECTION
 FIRST TRIALS INHOUSE
CASTING TRIALS LOW PRESSURE

CAREFULL PREPARATION & INSPECTION THROUGH CASTING TRIALS

FIRST TRIALS INHOUSE
GREY IRON CASTING
FIRST TRIALS INHOUSE
GRAVITY CASTING
 AGENDA
1.-AURRENAK:
• OUR MISSION

• BACKGROUND & PRODUCTS

• FOUNDRY GROUP WITH LORAMENDI

2.-TOOLING MANUFACTURING, “Q C D TARGET”:

• CUSTOMER ORIENTED ORGANISATION

• FROM DRAWING TO ENGINEERING

• MANUFACTURING CORE PROCESS CAVITIES

• FIRST TRIALS INHOUSE & CORRECTIONS

• MANUFACTURING IMPROVEMENTS
 FACILITES IMPROVEMENTS
HIGH SPEED MACHINES

• FIDIA K211, K165, D165

• MAZAK FJV, AJV
• MIKRON VCE WORN-NC
• LAGUN GVC POWER MILL
 PROCESS DEVELOPMENT
• HIGH SPEED ROUGHING:

– INCREASE METAL CUT OUT VOLUME

– IMPROVED NON CUTTING TIMES

– CAM PROGRAMMING

THERMAL FITTING

0,5 MM STOCK
PLUNGER
 PROCESS DEVELOPMENT
MACHINING IMPROVED AVOIDING EDM
FINISHING BY MATERIAL CAM MACHINING INSPECTION EDM POLISHIN TOTAL RESULT

EDM 32 10 120 20 125 45 320 100%

MACHINING 0 23 189 8 0 20 240 -25%

SPECIAL TOOL WITH

DRAFT & DIAMETER
2,5MM
 PROCESS DEVELOPMENT
AUTOMATIC TOOL CHANGE & MAGNETIC TABLE

• REDUCING SETTING UP TIMES AT MACHINE

MAGNET TABLE
LASER MEASUREMENT
 PROCESS DEVELOPMENT
AUTOMATIC ELECTRODE HOLDER

• REDUCING SET UP TIMES & ERRORS VIA “EROWA” HOLDERS

 PROCESS DEVELOPMENT
AUTOMATION ON CMM INSPECTION

CASTING TYPE

CLUTCH MISSION
BED PLATE
HOUSING HOUSING

MANUAL INSPECTION 120 90 75

AUTOMATIC INSPECTION
(OFF LINE PROGRAMME) 60 50 40

TOTAL REDUCTION 50% 44% 46%

 PROCESS DEVELOPMENT
BEST CUTTING CONDITIONS INVESTIGATION

EACH OPERATION OF EACH MATERIAL

REQUIRES INVESTIGATION FOR:

1. MINIMUN COST OF CUTTING TOOL

2. BEST CUTTING CONDITIONS & LIMITS

BEFORE FAILING

3. BEST QUALITY
AVOID PREVIOUS ERRORS
ASSEMBLY MANUAL
 NEW TECHNOLOGY IMPLEMENTATION
HIGH SPEED MACHINING & 5 AXIS KNOW-HOW

HIGH SPEED MACHINING, UP

TO 24.000 RPM

SPECIAL HARD METAL CUTTING

TOOLS, UP TO 1mm BALL END MACHINING AT 60º
 OPTIMISED PROCESS
WATER JACKET MANUFACTURING PROCESS

3D DESIGN COPY ROUGHING HEAT TREATMENT

 OPTIMISED PROCESS
WATER JACKET INSERT MANUFACTURING PROCESS

FINISHING INSPECTION NITRIDING

 TODAY CHALLENGE

SIGNIFICANT TOOLING COST REDUCTION

• TECHNOLOGY INHOUSE & SUPPLIER

• INNOVATION FROM EARLY DESIGN TO DELIVERY

• MANAGEMENT OF PEOPLE & RESOURCES

• COLLABORATION BETWEEN TOOLMAKER, STEELMAKER &

FOUNDRY