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Lived development partnership

People, machines and technologies have changed in the more than 50-year company history, the main goal of POWER-CAST Drumeta GmbH, however, has remained the same to this day: Optimally tailored zinc die casting solutions for customers. 

Complex components, sophisticated surfaces, highest precision and smallest tolerances: "When the competition reaches its limits, we take on challenges that seem impossible from almost all industries," says Design Manager Oliver Ihle. The combination of high production depth (over 90%) and state of the art heat chamber die casting machines (closing force of 200 - 2000 kN) and many years of expertise in the industry and unique ideas, POWER-CAST Drumeta offers the best conditions for the realisation of complex zinc die casting components.

'Substitution of an expensive laser sinter component by zinc die casting'

This is the goal of a development partnership between POWER-CAST and a customer who specialises in the manufacture of high-precision gear engineering. Due to long process times, low output quantities and quick wear of the moulds, the costs for a laser sintered ring gear were three times as high as a comparable zinc die cast part. Due to the helical inner teething of the ring gear, which is crucial for a quiet application in a planetary screw assembly (e.g.) within a door drive, the engine builders thought there is no alternative for laser sintering: A damage-free release of the component in die casting was not conceivable.

Benefits

-  Weight reduction of components by 10%

- Short process times

- Higher output quantities

- Longer mould life 

Therefore, the development partnership focused on the issue whether a cast component with helical inner teething without time delays and cost-intensive tool changes or elaborate retrofitting was possible. Taking into account both design and casting-specific parameters, POWER-CAST Drumeta developed a highly-complex release mechanic for helical inner teething. 'Highlight' of the solution is an integrated mechanical drive in the mould, which is precisely coordinated with the form-giving core of the helical teething. This drive works in synchronization with the standard release process. In a next step, a cut-out system for the component was set up with the aid of a modern form filling stimulation software. Oliver Ihle explains: "For example, with the simulation, we discovered minimal air inclusions at the end of the cast, which caused noise and made it necessary to perform subsequent work on the teething."

Cast release for helical gearing exceeds customers' expectations

In close coordination with the customer, the viability of the cast was then validated with the creation of a prototype - here, our joint expectations were already exceeded in the first casting trials. Furthermore, an additional saving could be gained for the customer due to a weight reduction of the components by 10%. Finally, the positive result was put into series. Today, casts for five additional variants have been implemented and in total, around 50,000 ring gears have been manufactured. POWER-CAST Drumeta was able to meet the customer's requirements in full with regard to the technical realisation, and with cost savings of around 70% (compared to unit costs for laser sintering), even the commercial aspect was exceeded.

Zinc die casting solutions accurately coordinated to customers' requirements

The combination of high production depth (over 90%) and state of the art heat chamber die casting machines (closing force of 200 - 2000 kN) and many years of expertise in the industry and unique ideas, POWER-CAST Drumeta offers the best conditions for the realisation of complex zinc die casting components.