The Design and Production of Light Metal Castings at Volkswagen

The general principles of design, casting, and the ensuing machining of light alloy parts in the Volkswagen factory are described. The paper discusses conditions peculiar to a rear-mounted engine as well as the design of parts for die casting and mold casting. A description is given of the efforts towards automation of die casting procedures. The measures to protect the smelt from oxidization, as well as methods of cooling and ventilation of the die, are also detailed. Emphasis is placed on the different conditions involved in the machining of aluminum and magnesium castings, and a comparison is made of tool service life.