MoldMaking Technology

SEP 2017

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moldmakingtechnology.com 49 Molded to Perfection With over 160 years of steel production experience backing their brands, SCHMOLZ + BICKENBACH is not only a pioneer, but also a market leader in specialty steels. Their comprehensive range of Formadur® and MoldMax® grades allows you to choose the ideally suited mold material for your application. In addition, an extensive range of value added services provides you with more alternatives from one source, SCHMOLZ + BICKENBACH. www.schmolz-bickenbach.us www.schmolz-bickenbach.ca Phone: +1 800 323 1233 their profile several times over their lengths. As a result, the new tools are, on average, about 10 percent stiffer and, in some cases, 40 percent lighter than conventional tools. With no detrimental effects on quality, this allows the num- ber of strokes in the press, which is between nine and 18 per minute, to be increased by one to two. The bottom line is that about 10 percent less energy is required for the press process and for the transportation between tool changes. Audi's spe- cialists estimate that the use of each new tool, assuming it has a lifetime of seven years, can reduce CO 2 emissions by an aver- age of at least 10 percent. Additive manufactured, optimized design. Additive manu- facturing offers similar design optimizations for car compo- nents, tools and molds. The Audi Toolmaking division is home to a newly established Metal 3D Printing Center. Here, special- ists from Audi Toolmaking collaborate closely with experts from the Casting Technical Center of Production Planning in Ingolstadt. There, 15 casting engineers from Neckarsulm and Ingolstadt develop new technologies and produce small series magnesium and aluminum die-cast parts like chassis compo- nents. The center hosts two cold chamber die-casting plants as well as aluminum and magnesium smelting systems. In cooperation with the Technical Development division, the Casting Technical Center uses its three metal printers to produce steel and aluminum parts for testing in engines and suspension. The Technical Development division in Ingolstadt houses nearly 9,000 employees at its approximately 82.8-acre complex. Another 1,700 employees work in Neckarsulm. With 3D metal printers in the Casting Technical Center, the goal is to better understand printed aluminum materials and the production technology. Various automobile parts are pro- duced, like space-frame components that integrate fluid con- tainers and suspension components. Also, Audi has recently entered a development partnership with EOS. "With their addi- tive manufacturing technology, we can integrate internal struc- tures and functions in tools that has not been possible with conventional manufacturing. Now we can quickly and eco- nomically produce components using lightweight construction, especially with components in small batches," Spindler says. Additionally, Audi will focus on producing parts and vehicle components more cost-effectively with inserts for die casting molds and hot-forming tools that use conformal cooling. This optimized cooling performance can reduce cycle time by 20 per- cent, decreasing energy consumption and cost. Audi's toolmaking division is well prepared for future chal- lenges. The entire industry faces enormous challenges in the fields of powertrains and digitization, and Audi is not resting on its laurels. CONTRIBUTOR Barbara Schulz is Gardner Business Media's European correspondent. She can be reached at bschulz@gardnerweb.com.

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