Audi 2015 Annual Report Download - page 45
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 |
 |
02 // FORWARD, BACK, FORWARD,
BACK AGAIN. Relentlessly, the high-
performance milling insert travels
to every corner. Only diamonds are
harder. Metal chips cover the gentle
curves, and gradually build up. Another
one-
thousandth of a millimeter is cut –
from
an uneven surface here, a transi-
tion there. Everything that could get in
the way must go.
Once the blank has been returned from
the foundry to the Audi plant, its many
curves and cut-outs make it plain to see –
the ultra tool generation is bionic. In
toolmaking, the forms and processes
found in nature are replicated to boost
the rigidity of the tools and cut the
amount of material required. Weight
can be reduced by as much as per-
cent compared with traditional tools.
In the lower tool part, for instance, these
reductions can add up to as much as
. metric tons. This signifi cantly cuts
the amount of energy needed to oper-
ate the tools.
Now it is time to fi ne-tune the tool.
Using a high-performance milling insert,
the press tool is precisely reworked to
eliminate even the tiniest rough spot
and thus to guarantee premium quality
in the pressing process.
Six of these tools – that is, six top and
six lower sections, each weighing around
metric tons – are needed to produce
an Audi Q fender from a fl at metal
blank. The goal of the toolmaking team
is to continuously reduce the weight of
the tools in order to support sustainable
production.
innovate.now! 044 >> 045