A new methodology in the design of an ultra-lightweight gearbox cover for the electric powertrain of a passenger car has been realized. Using an improved Vacural® die casting process from FRECH, the quality of the casting was increased, and an additional weight reduction of 34 percent was achieved.
Improvement of quality and reducing of weight through innovative die casting solutions
“I am glad to hear that FRECH has received the “IMA Award of Excellence for Processes”. This award is a significant achievement and underlines the company's innovative strength and expertise in the field of die-casting solutions, especially in the context of electromobility. The collaboration in the project consortium shows how important partnerships are for the development of advanced technologies”, Dr Thomas Franco, Chief Technology Officer of Oskar Frech GmbH + Co KG, stated. The project consortium developed a design methodology for ultra-lightweight transmission covers for the electric drivetrain of passenger cars.
"By substituting magnesium for aluminum, an initial weight savings of 25 percent compared to a reference component was able to be achieved. Building on this, a further weight reduction of 34 percent was achieved with the use of an improved Vacural® die casting method from FRECH. In addition to improving the casting quality, the overall weight of the gearbox cover was cut in half," explained Dr. Franco, referring to the possibilities. Electrified drive concepts, consisting of complex casting housings with integrated gearboxes and motors and a variety of attachment parts, offer the foundry industry new fields of application. "The Vacural® die casting method has proven to be ideal for manufacturing complex lightweight components in the development of lightweight construction structures in connection with electromobility. With high casting quality, the weight reduction of the final product achieves both significant material savings as well as a reduction in CO2 emissions," said Dr. Franco.
Further information about "IMA-Award of Excellence:"
The "IMA-Award of Excellence" is awarded annually by the International Magnesium Association (IMA). It recognizes companies, innovative products and manufacturing technologies for the varied application possibilities of magnesium. The IMA Award is awarded in six categories: Automotive Cast, Commercial Cast, Process, Wrought, Environmental Responsibility and Future Technologies in Magnesium. The project consortium received the award in the category of Process.
See https://www.intlmag.org/page/showcase2024-process for more information.
More about the "InDrutec-E" project:
The goal of the "InDrutec-E" project (Innovation leadership in die casting technologies for electromobility) is to achieve and further expand technological leadership in the field of die casting of lightweight metal alloys through innovative developments, including in the field of electromobility. To this end, novel material and manufacturing process innovations are developed, optimized for the changing requirements profile of the electrical drive train, intended to enable lower component weight at lower cost, lower CO2 emissions and improved component quality. There are multiple innovative technology routes for cost-effective and CO2 emissions-reducing lightweight construction in the field of die-cast components, which have the potential to reduce weight in individual component areas of electric vehicles by 15 to 35%. As partners in the project, the companies Robert Bosch GmbH, Oskar Frech GmbH + Co. KG and Gühring KG work together with the University of Aalen and the DLR Institute for Vehicle Design (Project Management) on the technological developments mentioned above. They are supported by the associated partners Andreas Stihl AG & Co. KG and EJOT GmbH & Co. KG.
