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Aluminum casting products are a key component in aerospace and mobility. Since aluminum is lightweight and has a high strength-to-weight ratio, it also has many applications in the electrification of drive systems. The production of stator housing for electric drives, for example, is a combination of casting, heat treatment, and machining processes. Stator housings are thin-walled parts subjected to heavy distortions after machining the main stator housing central boring since residual stresses stemming from the casting and heat treatment process are released. Classical process improvement techniques solely focus on each chain in the process link: casting, heat treatment, and machining. Due to new frameworks and digital data transfer platforms, data transfer from and to other process chain links is possible. We present a holistic approach for process improvements along the whole process chain using digital twins, which are built from experiments and simulations of each process link.

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Integrated Data-Based Process Chain in Casting and Machining: A Concept for Holistic Process Improvements

  • 会议论文

  • 发表日期：

    2025年

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  • Tim Reeber,
  • Martin Sicking,
  • Georg Fuchs,
  • Severin Maier,
  • Lucas Helml,
  • Alexander Kirnbauer,
  • Hans-Christian Möhring,
  • Dirk Biermann,
  • Wolfram Volk,
  • Friedrich Bleicher,
  • Paul Heinz Mayrhofer

摘要

Aluminum casting products are a key component in aerospace and mobility. Since aluminum is lightweight and has a high strength-to-weight ratio, it also has many applications in the electrification of drive systems. The production of stator housing for electric drives, for example, is a combination of casting, heat treatment, and machining processes. Stator housings are thin-walled parts subjected to heavy distortions after machining the main stator housing central boring since residual stresses stemming from the casting and heat treatment process are released. Classical process improvement techniques solely focus on each chain in the process link: casting, heat treatment, and machining. Due to new frameworks and digital data transfer platforms, data transfer from and to other process chain links is possible. We present a holistic approach for process improvements along the whole process chain using digital twins, which are built from experiments and simulations of each process link.