Thesis Worker: Geometry demand value stream mapping sheet metal floor compared to mega casting floor

Thesis Worker at Volvo Cars
Welcome to explore the world of Volvo Cars by writing your thesis with us! As a thesis worker in our organization you are supported by a supervisor who follows you during your project. All thesis projects are arranged in business critical areas and therefore you will be able to contribute to our company purpose – providing freedom to move in a safe, sustainable and personal way – from day one!

About this opportunity – Background
The automotive sector is facing disruptive changes. Harmful emissions must be decreased, and electric vehicles (EVs) are becoming the new standard. Weight reductions are always searched for, but the batteries in the EVs actually add extra weight. Light-weight materials can to some extent compensate for this and are becoming increasingly popular. To enable circular material flows and reduce the climate footprint of electric cars, new materials, and production methods are needed. Volvo Cars pioneers in this context by introducing “mega castings”. Also, other vehicle manufacturers are introducing more cast aluminum parts to reduce cost and weight and to prepare for circular material usage. Mega castings reduce complexity in production by enabling between 70 to 100 parts to be replaced by one single large die-cast part.
 

This master thesis will be a part of a research project “Geometrical robustness for mega casted aluminum parts (GROMCAP)” within the work package that cover comparison of a mega casted aluminum body structure and a traditional welded sheet metal structure.

For the industry to reach the high-set goals for sustainability and cost, it is of high importance that the production of large, single die-cast parts (mega castings) made out of recycled aluminum are robust to variations and disturbances in the production process. In GROMPCAP, methods to increase robustness with respect to factors affecting geometrical (also called dimensional) quality of a mega casting and the final product containing mega castings will be suggested. 

Mega castings need to be integrated into the car body design and even though joining operations are reduced due to the integration of parts, the remaining joints will be even more important, and the quality of these joints is critical to fulfill requirements such as strength and crashworthiness.
The goal for this master thesis is to investigate how to optimize geometrical quality versus cost. From the casting process there will be a certain geometrical quality outcome. In the following after-treatment steps the part can undergo additional processing such as straightening, machining and drilling. To overcome the geometrical quality outcome quality loops to the casting die could also be performed to compensate for a distortion. This improves the quality outcome to a certain degree, but it also affects the cost and time. We need to understand how does this casting assembly perform compared to a traditional sheet metal body structure with spot welding with respect to cost and total geometrical quality.
 

Scope of the thesis work
In this work a detailed study of collected measurement data of a traditional sheet metal floor assembly and of a mega casted part is to be performed and create a Geometrical deviation- to-cost relationship. 

•    Literature study to understand and map high pressure die casting process post processing alternatives
•    Perform workshop and interviews with experts within casting, machining and manufacturing engineering to map cost for post processing.
•    Perform cost walk & create a Geometrical deviation- to-cost relationship
•    Perform geometrical quality comparison 

The goal is to establish a deeper knowledge about the cost effects on the post processing and establish a way of working for way forward regarding back-up solutions as compensation quality loops, machining, straightening etc. within the research project.

What you´ll bring
Education in Mechanical engineering with masters programme in Product development, Process or Industrial management Engineering. Previous knowledge in cost walks/value chain mapping,  geometry assurance, data mining and tolerance chain simulation software is desirable. We wish for the students to be on site but for certain time remote work can be accepted, for example during literature studies. 

Duration
•    The work will start in January 2025, exact date to be discussed
•    The duration for this thesis work is 20 weeks.
•    30 ECTS (academic credits) if in agreement with your Thesis Advisor in University
•    This thesis is to be conducted by 2 Students working in pair. 

Be part of the change – apply today!
Applications should include  your CV and a brief personal letter stating your interests within the given area and your thoughts and credentials. We are continuously screening applications and will fill the position as soon as we find a good match. So do not hesitate to send in your application.
 
Apply as soon as possible but no later than  2024-10-31
Please note that due to GDPR applications via email will not be accepted.
If you want more information about the project or simply learn a bit more about the team, please reach out to:
Industrial Supervisor, Josefin Hansen at josefin.hansen.2@volvocars.com

Manager, Antonio D’Elia at antonio.delia@volvocars.com 
Academic Supervisor, Martin Roth at martin.roth@chalmers.se

Volvo Cars - Driving change together
Volvo Cars’ success is the result of a collaborative, diverse, and inclusive working environment. Today, we are one of the most well-known and respected car brands, with around 43,000 employees across the globe. At Volvo Cars, your career is designed around your skills and aspirations, allowing you to reach your fullest potential.