Geometrical robustness för mega casted aluminum part (GROMCAP)

Research Project, 2023 – 2026

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 automotive sector is facing disruptive changes. Harmful emissions must be decreased, and electric vehicles (EVs) are becoming the new standard. Weight reductions are always searched for, but the batteries in the EVs actually add extra weight. Light-weight materials can to some extent compensate for this and are becoming increasingly popular. To enable circular material flows and reduce the climate footprint of electric cars, new materials, and production methods are needed. Volvo Cars pioneers in this context by introducing “mega castings”. Also other vehicle manufacturers are introducing more cast aluminum parts to reduce cost and weight and to prepare for circular material usage. Mega castings reduce complexity in production by enabling between 70 to 100 parts to be replaced by one single large die-cast part. These single-piece castings will generally be produced close to the automotive assembly line, which allows for better integration and reduced transport. Enabling a circular material flow using recycled aluminum is important both from a sustainability and a cost perspective since production of recycled aluminum uses 90% less energy than primary production of aluminum (i.e. non-recycled material) and raw material is a critical resource.
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 suggested work packages cover identification of sources of geometrical deviation and variation, development of methods for simulation of geometrical quality, comparison between sheet metal assemblies and assemblies including mega castings from a geometry and cost perspective, and a suggestion of a geometry assurance process for products containing mega castings. The simulation methods will be implemented in an existing simulation platform, developed by the research group and in use by industrial partners.
The geometry assurance research group at Wingquist Laboratory/Chalmers and Volvo Car Corporation (VCC) have initiated this application. Chalmers is the main applicant and project leader of the project and VCC is the problem owner. The project advocates simulation as an important tool for efficient geometry assurance and therefore, also the software companies RD&T Technology AB and ESI Group will participate in the project.