Novel methodology in designing an ultra-light gearbox cover for the electrical drive train of a passenger vehicle was recognized. The quality of the casting was increased and an additional weight reduction of 34 percent was achieved by using an improved Vacural® die casting method from FRECH.
Quality increase and weight reduction through innovative die casting solutions
"We are very pleased to receive the IMA-Award of Excellence for Processes. This honors FRECH's comprehensive expertise in innovative die casting solutions for developing lightweight structures in connection with electric mobility. We are thankful to our partners for their excellent collaboration," said Dr. Thomas Franco, Chief Technology Officer of Oskar Frech GmbH + Co. KG. FRECH was recognized as a member of a project consortium of renowned and leading companies and institutions. With the project "InDrutec-E," this consortium has taken on the mission of taking over technological leadership in the field of die casting of lightweight metal alloys through innovative developments, including in the field of electromobility. The project consortium developed a design methodology for ultra-light gearbox covers of the electrical drive train for passenger vehicles. This provides an additional lightweight construction potential of 15 to 35 percent in bearing applications such as housings and covers, through the use of magnesium.
"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, making reference 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.
About the "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.
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.