Automotive Endshield
as a media-tight metal substitute
Use of the latest lightweight construction technologies as a driver for a more economical and better pump component.
Lightweight solutions have long since ceased to be an option in the automotive sector and are now standard. If it is also possible to improve elementary product properties and reduce costs by more than 300%, we are talking about a genuine next-gen solution.
# Initial situation
High susceptibility to defects and competitive disadvantages in aluminum die casting.
On behalf of a well-known Tier 1 supplier, we took over the optimization of an existing automotive endshield assembly, which had previously been manufactured in aluminum die casting at great expense and with high wear rates.
The end cap is part of a transmission oil pump that lubricates the automatic transmission in various hybrid vehicles and initiates gear changes. The originally chosen aluminum die casting process has a considerable potential for error.
In order to realize the functions in the cover, the die casting must then be mechanically processed. The casting skin is opened during this machining process. If the casting exhibits process-related porosity at this point, the pump will end up leaking and the risk of leakage will increase.
In addition, the manufacturing process in die casting is particularly cost-intensive with a high proportion of mechanical processing. The technology-related short tool life compared to plastic also significantly increases the total cost of ownership.
”We think of the product and the process in plastic. We can do this because we have unique experience in the processing of thermosets and the substitution of metals.
Marco WirthChief Sales Officer
Optimizations in the component based on state-of-the-art simulations and calculations
In a coordinated process, opportunities and solutions are identified together with the customer, which our development teams then translate into a plastic-compatible concept with defined milestones.
To this end, we use filling simulations and strength calculations to develop a valuable basis for decision-making, which we use to optimize the design of support structures, geometry and wall thicknesses. The component design and the positioning of the reinforcing ribs are decisive for the required mechanical and thermal load capacity as well as the high tightness requirements. It is particularly important to achieve maximum tightness and resistance in the plastic on the shaft.
# Market advantage
Cost and weight advantages at all levels.
11,234
Weight reduction
The reduced density from 2.75 g/cm3 to 2.08 g/cm3 and the optimized geometry of the thermoset ensures a weight saving of up to 23%.
300
Cost savings
By switching to thermoset, we save a large part of the cost-intensive post-processing and assembly steps, as machining is no longer necessary due to the technology and the required functions can be integrated efficiently. At the same time, wear and rejects are significantly reduced.
150.000
More efficient production
Faster production at the site and significantly longer tool service lives
we accelerate the time to market and the quality of the process.
Optimum tightness
Thanks to the high-precision processing properties of the thermoset material with tolerances of a few hundredths of a millimeter and the high surface quality in the µm range, we can meet all of the customer’s sealing requirements.
Dimensional stability
Even under high temperatures or extreme loads, the end cap retains its shape and remains dimensionally stable thanks to its low coefficient of linear and thermal expansion.
Greater energy efficiency
Significantly less primary energy is used in the production of the thermoset Vyncolit® X7320 than in the melting of the comparatively energy-intensive aluminum die casting.
# Hidden Champion DuroPlast®
Duroplast as a better alternative to die-cast aluminum.
Despite all the lightweight construction and economic efficiency efforts in the automotive segment, the majority of components in vehicles are still made of metal or thermoplastics. This is often due to a lack of knowledge in process and testing technology, as the characteristic thermoset properties are only created by the complex cross-linking process in the injection mold.
With an experienced partner like the GAUDLITZ HUB, you can translate these opportunities into a production-ready manufacturing concept that gives you a tangible advantage over your competitors. Especially in media-tight metal substitution or in the immediate engine compartment environment, thermosets are ideal for producing a resistant, compact and lightweight component.
# Know-how
Duroplast
Duroplast is a pressure-resistant plastic for the highest mechanical stresses and is particularly suitable as a substitute for die-cast aluminum or die-cast zinc. In contrast to thermoplastic materials, pressure in the mold creates an irreversible chemical cross-linking. After hardening, these materials can no longer be converted into a plastic deformable state.
# Next Gen Projects
Together we create Next Gen Solutions.
“We know the production side and have the development expertise. Only those who understand both sides and bring them together will be able to demonstrate a competitive edge.”
Chief Sales Officer
