Casting Re-design

We were approached by MG Rover via one of their casting suppliers.

The task was to carry out a cost down exercise on the K Series aluminum sump as part of BMW’s compete program.

The goal of our part of the program was to save £1 million over the remainder of the K series life expectancy. One of the specific tasks was to change the process from a gravity die cast solution to an high pressure die casting. This meant the design would require modification to accommodate the new manufacturing process in turn resulting in new tooling requirements.

Carrying out this task gave us the opportunity to look at the design in more detail and highlight possible design improvements while maintaining form, fit, & function. Due to the sump being in circulation on a number of vehicles such as the as the Freelander it was important to manage the project & communication with all vehicle model teams was key to the success of the project.

Working closely with both the toolmaker Preconomy & the casting manufacturer Transtec in Lincoln we were able to achieve our goal in a timely manner and within budget.

 

 

 

  • 3D Cad Design Pro Engineer (Casting & Machined models)
  • Flow Simulation (External support)
  • Finite Element Analysis (External Support)
  • Design Reviews
  • Detailed Machine Drawings
  • Suppliers & Customer Liaison
  • Project Management
  • Manufacturing Support

 

Processes Involved

 

  • 3D Cad Design Pro Engineer (Casting & Machined models)
  • Magma flow
  • Design Reviews
  • Detailed Machine Drawings
  • Suppliers & Customer Liaison
  • Project Management
  • Manufacturing Support

 

                                                                           Images used with kind permission of Volkswagen Group