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Bm wengl ceeng Lost Foam
- 1. BMW´S LOST FOAM FOUNDRY WITH WIDE OPEN THROTTLE FOR THE NEW CENTURY Presented by Karel Cermak, Vulcan Engineering Co. Represented by Framewell International Ltd., Beijing
- 3. 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 kW L/F CASTING
- 4. DECISION CRITERIA REDUCTION OF INNOVATIVE MACHINING STEPS COMPONENT DESIGN FLOOR SPACE REDUCTION POTENTIAL FOR FURTHER WEIGHT REDUCTION POSITIVE COST ADVANTAGE MODIFICATION FRIENDLY IMPROVEMENT OF ENVIRONMENT
- 5. PROJECT PHASES Green Light 1992 Pilot Plant 1993 First Casting 1993 Technology Qualification 1995 Production Start 1998 1500 Castings per day 2000 1992 1994 1996 1998 2000 2002
- 6. FACTORS OF SUCCESS INTEGRATION OF ALL FOR PROJECT MANDATORY DISCIPLINES FROM VERY BEGINNING
- 7. FACTORS OF SUCCESS IDENTIFICATION AND CLASSIFICATION OF ALL PROCESS RELEVANT STEPS IN THE LOST FOAM
- 8. FACTORS OF SUCCESS TO FURNISH NECESSARY RESOURCES
- 9. FACTORS OF SUCCESS MANAGEMENT OF RISK AND TRUST
- 10. PARTNERS SELECTION VULCAN ENGINEERING AND MANUFACTURING COMPANY - THE LEADER IN REALISATION OF LOST FOAM SYSTEMS WAS INVOLVED FROM THE PILOT THROUGH TO PRODUCTION PHASE
- 11. Headquarters: HelenaAlabma, USA Worldwide Representation Cmplete foundry systems 150 Engineers uropean Manufactring: Leicester, UK Of 79 Lost Foam lines in the Wold, 47 built by us
- 12. JOB DESCRIPTION FROM BEAD´S EXPANSION THROUGH CASTING EXTRACTION
- 13. THE BMW LOST FOAM FLOW
- 14. Raw material with blowing agent Preexpansion Steam heat applied Moulding EPS expanded factor ca. 30 Density control critical Stabilisation Glueing Coating Drying Cluster Insertion Sand Fill Compaction Metal Pouring Extraction
- 15. EPS beads filled into Al tool Preexpansion Steam heated to expand and fuse Moulding Cooled to avoid distorsion Automatic removal Stabilisation Glueing Coating Drying Cluster Insertion Sand Fill Compaction Metal Pouring Extraction
- 16. Controlled shrinkage Preexpansion Accelerated processing Moulding Repeatability 0,2 Stabilisation 0,1 0 Glueing -0,1 0 100 200 300 400 Coating -0,2 With Stabilisation Oven -0,3 Without Stabilisation Oven Drying -0,4 -0,5 Cluster Insertion time (mins) Sand Fill Compaction Metal Pouring Extraction
- 17. Hot melt glue Preexpansion Short “open time” Moulding Repeatability Accuracy Stabilisation Glueing Coating Drying Cluster Insertion Sand Fill Compaction Metal Pouring Extraction
- 18. Coating developed for lost foam Preexpansion Repeatability Moulding Ceramic slurry Precise viscosity/solids Stabilisation Glueing Coating Drying Cluster Insertion Sand Fill Compaction Metal Pouring Extraction
- 19. Removal of all moisture Preexpansion Temperature/humidity controlled Moulding Stabilisation Glueing Coating Drying Cluster Insertion Sand Fill Compaction Metal Pouring Extraction
- 20. Preexpansion Moulding Stabilisation Glueing Coating Drying Cluster Insertion Sand Fill Compaction Metal Pouring Extraction
- 21. Dry unbonded sand Preexpansion Rain-fill Moulding Uniform Rate controllable Stabilisation Glueing Coating Drying Cluster Insertion Sand Fill Compaction Metal Pouring Extraction
- 22. Fluidisation - Compaction Preexpansion Precise control Moulding Stabilisation Glueing Coating Drying Cluster Insertion Sand Fill Vibration Analysis 5,0 5 FFT Analysis 4 Compaction 2,5 3 0,0 2 Metal Pouring -2,5 1 0 -5,0 -1 Extraction 0 25 50 75 100 0 25 50 75 100 ms Hz
- 23. EPS liquified and volatised Preexpansion Metal replaces foam Moulding All details reproduced Stabilisation Glueing Coating Drying Cluster Insertion Sand Fill Compaction Metal Pouring Extraction
- 24. No shakeout Preexpansion Sand dry and loose Moulding Sand easily recycled Stabilisation Glueing Coating Drying Cluster Insertion Sand Fill Compaction Metal Pouring Extraction
- 25. RESULTS CONSEQUENTIAL IN PROJECT, PROCESS MANAGEMENT&TOTAL COMMITMENT
- 26. RESULTS PROJECTED CAPACITY OF 1.500 CASTINGS ARE PRODUCED IN 3 SHIFTS NOW
- 27. RESULTS OVERALL EQUIPMENT EFFECTIVENESS OEE > 0.75 ! !
- 28. RESULTS 26 % COST SAVINGS ! !
- 29. FACTS MORE THAN 400.000 „LOST FOAM“ BMW´S ARE ON THE ROAD TODAY
- 30. FACTS VULCAN ENGINEERING´S EXPERIENCE , EXPERTISE & TOTAL SYSTEM APROACH WAS INSTRUMENTAL TO BMW SUCCESS.