Development of a digital production process for the economic manufacture of near-contour cooling systems; development of a casting and coring process for hybrid lost moulds
Start of a research project within the framework of the “Central Innovation Programme for SMEs (ZIM)” under the sponsorship of the AiF with the partners voxeljet AG, the Fraunhofer Institute for Silicate Research (ISC) and the Fraunhofer Research Institution for Foundry, Composite and Processing Technology (IGCV):
“Development of a digital production process for the economic manufacturing of near-contour cooling systems; development of a casting and coring process for hybrid lost moulds.”
Increasing power density – is the cooling of the engine. Water-cooled systems are particularly effective. Their effectiveness depends on the heat transfer to the cooling medium. Here, a large surface area and the spatial proximity to the heat source are advantageous. As a technical implementation of this cooling, a cooling jacket is placed around the current-carrying, laminated stator, in which cooling lines are inserted (cooling close to the contour). The light metal aluminium is a suitable material for this housing, as it has the same properties of low density and good thermal conductivity.
The channel structures can be realised by producing the component through a casting process with lost cores. The cores are removed from the component after casting by shattering the core, which has already been thermally damaged by the casting, via vibrations and impacts.
Particularly high levels of complexity can be achieved using additive manufacturing production processes. They also make it possible to reproduce the diversity of parts in the different performance and vehicle classes. Among the AM processes, binder jetting has the most favourable economic properties.
The resulting task for this project is the “development of a digital production process for the economic production of systems for contour cooling”. In the consortium, the sub-projects described below are being worked on in close cooperation: The Fraunhofer Institute ISC is researching a ceramic slurry for core production that can be processed in an AM process and also enables the desired properties of the component/core during the sintering process. The company voxeljet AG is developing a prototype printing system that enables the processing of ceramic slurry in an AM process on an industrial scale. The Fraunhofer IGCV experimentally determines all influencing variables on the component production process and makes the process comprehensible and optimisable through holistic modelling and simulation.
The foundry NRU GmbH is developing a process chain for the production of a metallic casting, with the decoring process for the novel, ceramic cores being the innovative core of the work. AMK, as an electric motor manufacturer and large enterprise, is a potential user of the products created via the digital production process and does not itself provide any sub-innovation relevant to the funding.
Start of the project: 01.07.2018