The introduction of mega and gigacasting processes is changing the automotive industry: single-piece structural components such as front or rear undercarriages and battery housings made of die-cast aluminium are replacing hundreds of individual components that have to be welded. This technology, used by Tesla and Volvo, for example, simplifies production, reduces weight and improves the rigidity of the components. At the same time, it places new demands on the post-processing of cast parts.

The focus of modern deburring presses is increasingly on the ergonomics, safety and efficiency of die changing – a core competence of ROEMHELD, the set-up time optimiser based in Laubach in central Hesse. This is because one of the key challenges in deburring large castings is the safe and precise handling of dies weighing up to 30 tonnes. Automated solutions are the first choice in terms of occupational safety and productivity, given the dimensions and weights involved. They are standard in fully automated plant concepts such as complete megacasting die-casting plants.

Depending on requirements, the dies are brought to the press by crane or transport trolley, lifted onto ROEMHELD hydraulic transport bars by vacuum suction cups or robots, and then precisely inserted into the press, where they are positioned and clamped. Removal takes place in reverse order.

90° swing sink clamps are used on the press ram, which are equipped in the same way as the clamping elements on the press table. "The ROEMHELD clamping technology in the press ram and press table ensures that even large-format, heavy dies are reliably fixed and held in position – crucial for process reliability and repeat accuracy in megacasting," emphasises Pfeifer. The tolerances of the clamping solution are a few tenths of a millimetre, which easily meets the required component tolerances.

All clamping elements are driven centrally by a ROEMHELD hydraulic unit, whose output is matched to the components. The modular element controls and monitors all functions. An energy-saving standby mode is automatically activated during production interruptions.

The clamping technology control system is integrated into the machine control system of the deburring press. It is based on a Siemens control system, which has been equipped with its own intuitive user interface by Aulbach Automation, and enables quick access to all processes.

The advantages of automated die change include reduced set-up times and increased process reliability. For the operator, the most important factors are improved ergonomics and safety when working on the press. While the frequency of die changes in the megacasting sector is typically low, the quality of the changeover process is paramount. Inaccurate positioning or incorrect clamping of dies can damage them and lead to faulty components, causing expensive production downtime.

In order to create the conditions for further growth, Aulbach Automation has built a new assembly hall with a 63-tonne crane capacity in 2024, where the large presses can be assembled in a standing position.

Krimm expects international demand for ever larger Megacasting deburring presses to grow steadily in the future. The machine manufacturer is therefore planning to expand the press sizes beyond the current dimensions. "We are also seeing that our customers' requirements are becoming increasingly individual," says the managing director. "In future, specific adaptations will certainly be necessary more often. With ROEMHELD as our partner, we are confident that together we will develop solutions that meet our customers' high expectations."