Clément Vigniel’s Post

🚗 Giga Casting: Revolutionizing Electric Cars, One Large Component at a Time 🚗 Giga casting is transforming the automotive industry by enabling the production of large, single-piece components that reduce weight, assembly time, and costs. However, such innovation comes with its own set of challenges: 🔧 Material Flow Issues: Ensuring uniform mold filling to avoid cold shuts or incomplete components. 🔥 Thermal Management: Large components retain significant heat, requiring precise cooling control. Uneven cooling can lead to thermal stresses, warping, or cracking. ⚠️ Defects: Shrinkage, porosity, gas entrapment, and other structural flaws that compromise quality. 💰 High Tooling Costs: Expensive mold design and maintenance, leaving little room for error. ⚙️ Production Complexity: Advanced machinery and precise control are essential for large-scale manufacturing. 📏 Quality Assurance: Ensuring defect-free, consistent quality across large parts is a major challenge. This is where FLOW-3D CAST steps in as the ultimate solution: ✅ Simulate Material Flow: Predict how molten metal behaves in the mold for uniform filling. ✅ Defect Prevention: Identify shrinkage, porosity, and thermal stresses before production begins. ✅ Thermal Optimization: Model heat transfer and cooling to prevent warping or cracking. ✅ Cost Efficiency: Reduce trial-and-error, minimize waste, and optimize production processes. Leading automakers like Tesla, BMW, Toyota, Stellantis, NIO, Daimler, Dongfeng Motor Corporation, and Audi trust FLOW-3D CAST to overcome these challenges and achieve exceptional results in giga casting. 🚀 Ready to transform your casting process? Let’s connect and explore how FLOW-3D CAST can help! In this video, we see the filling process of an electric-vehicle rear-underbody using "FLOW-3D CAST". The part is made of A319 LM4 aluminum alloy, which is poured at temperature of 640 degrees and velocity of 4 m/s. This kind of automotive components is typically divided into several subcomponents, which get assembled together later to form a complete part. With Giga casting presses, it is now possible to manufacture this part as a whole, single piece, in less than two minutes. "FLOW-3D CAST" can boost the design process and anticipate the problematic areas before bringing the design into reality. #elrefay #HPDC #GigaCasting #FLOW3DCAST #ElectricVehicles #AutomotiveInnovation #CastingSimulation #Efficiency #FLOW3D #cfd #arabworld

There’s a never-ending lightweighting challenge for Automotive manufacturers - reducing vehicle weight to deliver better fuel economy, longer battery life and better performance. This article explores how the development and progression of Electronics impacts this mission – and how In2tec’s innovation offers solutions to support and change electronics integration within the boundaries of automotive lightweighting. Read the full article to learn more 👉 https://lnkd.in/eMH_SEYb #AutomotiveDesign, #Automotive, #AutomotiveEngineering, #ElectricAndHybridVehicles

Today’s Differential Cases are unrecognisable compared to those that emerged in the 1820s. Discover how technology and the industrial revolution transformed this component for the better… #automotive #differentials #diffcases

Cutting exhaust emissions is critical to designing propulsion systems fit for the future. Simulation of exhaust system scenarios in real-time allows engineers to balance performance and reduce tailpipe emissions with the aim to get to as close to zero as possible, as soon as possible. The design challenge is finding the right balance between fuel economy, motorcycle, car or truck performance and the selection of the right exhaust aftertreatment components to reduce emissions inline with stricter regulations. The 2024.1 release of IGNITE, our Systems Engineering tool introduces new faster than real-time aftertreatment modelling to minimise emissions with an enhanced catalyst tuning process to calibrate 1D Three Way Catalyst models. This is particularly relevant in the motorcycle industry where component selection is critical to cutting emissions whilst achieving a lightweight, efficient machine construction. Find out more about how simulation software can help with exhaust aftertreatment modelling to cut overall tailpipe emissions. https://lnkd.in/eGH3Fm83 #motorcycle #motorcycles #automotive #emissionsreduction #emissionscontrol #exhaustsystem #catalyticconverter #systemsengineering #simulationsoftware

A test bench, or testing workbench, is an environment used to verify the correctness or soundness of a design or model, essential in modern industry for precision engineering. Test benches serve three main purposes: ➡ Prototyping and Innovation: They allow scientists to study and implement new technology prototypes by simulating real-world conditions, facilitating effective testing before commercial rollout. ➡ Improvement of Existing Technologies: Test benches enable the study of existing technologies to suggest improvements. For example, automotive engineers can manipulate parameters to enhance engine performance, as seen with Mercedes' high-performance AMG trims. ➡Reliability Testing: They are crucial for testing product reliability before delivery, identifying potential flaws, and developing maintenance schedules, particularly important in the automotive industry. Nowadays an automobile is very complicated and built of many complex parts which communicate data with each other in real time. Therefore, before rolling out a product testing is necessary. The main types of test benches which are used are engine test benches, battery pack test benches, cold test benches, hot test benches, leak test benches, hybrid electric motor test benches, and transmission test benches. As an aspiring automotive engineer I was fortunate enough to visit Center for Mobile propulsion (CMP), Aachen. The Center for Mobile Propulsion features twelve engine test benches for researching passenger car, commercial vehicle, and range extender engines. These benches, equipped with hydraulic systems, can accommodate engines up to 6 m x 9 m and handle outputs of up to 300 kW or 600 kW. They allow for longitudinal or transverse engine assembly, covering a wide range of performance parameters. The spacious design enables close placement of measurement technology to the test vehicles, supporting detailed research.

As the automotive industry undergoes a monumental shift towards electrification, the spotlight is increasingly focused on the intricate components that drive the performance and efficiency of electric vehicles (EVs). Among these components, the gearbox plays a crucial role in translating the power from the electric motor to the wheels, optimising performance while navigating the unique challenges posed by electric propulsion systems. Read more https://lnkd.in/gjebwe_N #gear #geartechnology #mechanicalengineering #mechanical #magazine #lubrication #industry #engines #tool #tools #mechanicaldesign #mechanics #machinelearning #machine #machinedesign #machinedparts #gearbox #automotive #app #productivity #lubrication #operations #machine #study #notes #engineering #study #articles #energy #economic #efficiency #technology #EV #electricvehicles #gearbox #gearboxdesign #automotive #automotiveindustry

Automobile engineering focuses on the design, development, manufacturing, and testing of vehicles. Understanding Vehicle Components: Knowledge of key components such as the engine, transmission, brakes, suspension, and chassis. Engine Technology: Familiarity with internal combustion engines (ICE), hybrid systems, and emerging technologies like electric and hydrogen fuel cells. Vehicle Dynamics: Understanding the forces acting on a vehicle, including aerodynamics, traction, and handling.

This is our most clicked formingworld post from May 💡 Facing unexpected splits during mass production, Nissan Motor Corporation launched a project to identify the influencing factors. Spanning two months, they examined 20 parts to identify the causes in the split areas. See the countermeasures they applied to enhance productivity in this post ❗ ➡ https://lnkd.in/e5UX_y7n #simulation #digitalengineering #tooling

Bunting has designed and built a bespoke industrial magnetiser for an automotive electric vehicle application. The latest industrial magnetiser magnetises a permanent magnet rotor assembly for a high-end automotive traction motor.Industrial magnetiser workstation tower with control and power supply Although Bunting builds a standard range of industrial magnetisers, the increasingly complex magnet assembly configurations and end-user requirements are driving the demand for bespoke models, especially in automotive and aerospace applications. Magnetisation in an industrial magnetiser occurs when a permanent magnet material or assembly is exposed to a high intensity magnetising field, driving the material into saturation to develop the full permanent magnetic properties. The required strength of the magnetising field is considerably higher than the intrinsic properties of the material and depends primarily on the type of material being magnetised. In this electric vehicle development a

A 20% boost in productivity for #electriccar transmission parts is driving efficiency and innovation in the #EVindustry. With advancements in manufacturing processes and precision engineering, this improvement not only accelerates production but also enhances the performance and reliability of electric vehicles. #ElectricVehicles #ProductivityBoost #EVInnovation #SustainableMobility #electronicsnews #technologynews