Challenges in Geometry Assurance of Megacasting in the Automotive Industry

Megacasting is a new concept in the automotive industry. A large number of sheet metal parts will be replaced with one large aluminum casting, i.e., a megacasting. This helps to reduce weight, opens up for larger design flexibility, allows for a more circular production, and takes away a large number of assembly steps in the production process. However, there are also challenges related to the use of megacastings. This position paper outlines challenges associated with the geometrical quality of the final product. It covers robust design and tolerancing in early product development phases as well as inspection preparation during pre-production and digital twin setup during full production to ensure the geometrical quality of a product containing a megacasting. Simulations of both part-level and assembly-level deviation and variation are discussed. The paper outlines a geometry assurance process for products containing megacastings in the automotive industry, and what research challenges that are the most important ones to address in this area. It is concluded that computer-aided tolerancing tools must be able to predict the dimensional effects from joining methods such as flow-drill fasteners or self-pierced riveting, to use casting simulation as input, and to handle combinations of solid and surface meshes. Furthermore, there might be a need for adjustments to the joining process based on digital twins to achieve proper quality at a reasonable price. Experiences in using megacastings in the body-in-white are lacking and a fast learning curve is required.