Geometrical robustness for mega casted aluminum parts (GROMCAP)

Purpose and goal:

The main problem addressed in GROMCAP is how to formulate a process for geometry assurance of products containing mega castings of recycled aluminum to increase robustness, reduce costs and improve quality.

The goal of the project is to create a process to secure stable, reliable, and verified concepts for the design of mega casted components with respect to geometrical quality. The work focuses on identification of sources of geometrical variation, development of methods for simulation of geometrical quality and to learn more about the geometry assurance of mega casted parts.

Expected results and effects:

Megacasting means that the number of parts in a product can be significantly reduced - a megacasting can replace 70-100 sheet metal parts and thus reduce complexity. Using recycled aluminum benefits a circular value chain. A geometry assurance process to support this provides better quality and reduced costs.

Approach and implementation:

The project consists of six work packages focusing on project management, identification of sources of variation, part simulation, assembly simulation, comparison between megacasting and traditional assemblies with respect to geometry, as well as a process for geometry assurance. The project is led by Chalmers in close collaboration with Volvo Cars.

The other actors, RD&T Technology and ESI Nordics, will contribute with simulations of the casting process and geometric quality for both individual components and assemblies.