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Giga Press
The Giga Press program is a series of aluminium die casting machines manufactured by Idra Group in Italy. They are notable for being the largest high-pressure die casting machines in current production, with a clamping force of . Each machine weighs . Base specification Giga Press machines had been included in Idra's catalogue since 2018, with usage of a customised Giga Press started by Tesla, Inc. in late-2020 for the production of chassis parts for the Tesla Model Y. Shots of molten aluminium weighing are injected into the cold-chamber casting mold with a velocity of . The cycle time is ~80‒90 seconds, allowing an output rate of 40‒45 completed castings per hour, or ~1,000 castings per day. Principle of operation Die casting works by forcing molten metal alloy inside a reusable mold, then opening the mold to remove the finished piece after it has solidified. The open mold is cooled to and cleaned by robots, and fresh molten aluminium is prepared for the next cy ...
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Tesla Factory
The Tesla Fremont Factory is an automobile manufacturing plant in Fremont, California, operated by Tesla, Inc. The facility opened as General Motors' Fremont Assembly in 1962, and was later operated by NUMMI, a GM–Toyota joint venture. Tesla took ownership in 2010. The plant manufactures the Model S, Model X, Model 3, and Model Y, employing 22,000 people . Background Tesla had planned for an assembly factory in Albuquerque, New Mexico, as a central location for shipping. Construction was supposed to begin in April 2007, but was canceled. A separate greenfield factory to be built in San Jose, California was also announced. However, the cost was prohibitive, and the company looked for alternatives. Tesla initially also dismissed NUMMI for being too big and costly. Some of the current facilities were operated as the GM Fremont Assembly from 1962 to 1982, and between 1984 and 2009 was used by New United Motor Manufacturing, Inc. (NUMMI), a joint venture between General Mo ...
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Argon
Argon is a chemical element with the symbol Ar and atomic number 18. It is in group 18 of the periodic table and is a noble gas. Argon is the third-most abundant gas in Earth's atmosphere, at 0.934% (9340 ppmv). It is more than twice as abundant as water vapor (which averages about 4000 ppmv, but varies greatly), 23 times as abundant as carbon dioxide (400 ppmv), and more than 500 times as abundant as neon (18 ppmv). Argon is the most abundant noble gas in Earth's crust, comprising 0.00015% of the crust. Nearly all of the argon in Earth's atmosphere is radiogenic argon-40, derived from the decay of potassium-40 in Earth's crust. In the universe, argon-36 is by far the most common argon isotope, as it is the most easily produced by stellar nucleosynthesis in supernovas. The name "argon" is derived from the Greek word , neuter singular form of meaning 'lazy' or 'inactive', as a reference to the fact that the element undergoes almost no chemical reactions. The complete octe ...
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Silicon
Silicon is a chemical element with the symbol Si and atomic number 14. It is a hard, brittle crystalline solid with a blue-grey metallic luster, and is a tetravalent metalloid and semiconductor. It is a member of group 14 in the periodic table: carbon is above it; and germanium, tin, lead, and flerovium are below it. It is relatively unreactive. Because of its high chemical affinity for oxygen, it was not until 1823 that Jöns Jakob Berzelius was first able to prepare it and characterize it in pure form. Its oxides form a family of anions known as silicates. Its melting and boiling points of 1414 °C and 3265 °C, respectively, are the second highest among all the metalloids and nonmetals, being surpassed only by boron. Silicon is the eighth most common element in the universe by mass, but very rarely occurs as the pure element in the Earth's crust. It is widely distributed in space in cosmic dusts, planetoids, and planets as various forms of silicon dioxide ( ...
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Aluminium Alloy
An aluminium alloy (or aluminum alloy; see spelling differences) is an alloy in which aluminium (Al) is the predominant metal. The typical alloying elements are copper, magnesium, manganese, silicon, tin, nickel and zinc. There are two principal classifications, namely casting alloys and wrought alloys, both of which are further subdivided into the categories heat-treatable and non-heat-treatable. About 85% of aluminium is used for wrought products, for example rolled plate, foils and extrusions. Cast aluminium alloys yield cost-effective products due to the low melting point, although they generally have lower tensile strengths than wrought alloys. The most important cast aluminium alloy system is Al–Si, where the high levels of silicon (4–13%) contribute to give good casting characteristics. Aluminium alloys are widely used in engineering structures and components where light weight or corrosion resistance is required.I. J. Polmear, ''Light Alloys'', Arnold, 1995 Alloys c ...
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Sandy Munro
Sandy Munro is an automotive engineer who specializes in machine tools and manufacturing. He started as a toolmaker at the Valiant Machine & Tool company – a General Motors supplier in Windsor. In 1978, he joined the Ford Motor Company where he improved methods of engine assembly. In 1988, he started his own consultancy, Munro & Associates, in Troy, Michigan, specializing in lean design, tearing down automotive products to study and suggest improvements and innovations. Now located in Auburn Hills, Michigan, the company performs electric vehicle benchmarking and consults in the aerospace, defense and medical sectors. In 2018, he started broadcasting video analyses and interviews on his YouTube channel, Munro Live. This now has over 300,000 subscribers and was successful in raising the profile of his consultancy during the COVID-19 pandemic, when meetings and trade shows were restricted. Early life Munro was born on 19. January 1949 and grew up in Windsor, Ontario, Canada. ...
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Environmental Impact Assessment
Environmental Impact assessment (EIA) is the assessment of the environmental consequences of a plan, policy, program, or actual projects prior to the decision to move forward with the proposed action. In this context, the term "environmental impact assessment" is usually used when applied to actual projects by individuals or companies and the term " strategic environmental assessment" (SEA) applies to policies, plans and programmes most often proposed by organs of state. It is a tool of environmental management forming a part of project approval and decision-making. Environmental assessments may be governed by rules of administrative procedure regarding public participation and documentation of decision making, and may be subject to judicial review. The purpose of the assessment is to ensure that decision makers consider the environmental impacts when deciding whether or not to proceed with a project. The International Association for Impact Assessment (IAIA) defines an enviro ...
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Laser
A laser is a device that emits light through a process of optical amplification based on the stimulated emission of electromagnetic radiation. The word "laser" is an acronym for "light amplification by stimulated emission of radiation". The first laser was built in 1960 by Theodore H. Maiman at Hughes Research Laboratories, based on theoretical work by Charles Hard Townes and Arthur Leonard Schawlow. A laser differs from other sources of light in that it emits light which is ''coherent''. Spatial coherence allows a laser to be focused to a tight spot, enabling applications such as laser cutting and lithography. Spatial coherence also allows a laser beam to stay narrow over great distances (collimation), enabling applications such as laser pointers and lidar (light detection and ranging). Lasers can also have high temporal coherence, which allows them to emit light with a very narrow spectrum. Alternatively, temporal coherence can be used to produce ultrashort pulses of ligh ...
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Industrial Radiography
Industrial radiography is a modality of non-destructive testing that uses ionizing radiation to inspect materials and components with the objective of locating and quantifying defects and degradation in material properties that would lead to the failure of engineering structures. It plays an important role in the science and technology needed to ensure product quality and reliability. In Australia, industrial radiographic non-destructive testing is colloquially referred to as "bombing" a component with a "bomb". Industrial Radiography uses either X-rays, produced with X-ray generators, or gamma rays generated by the natural radioactivity of sealed radionuclide sources. Neutrons can also be used. After crossing the specimen, photons are captured by a detector, such as a silver halide film, a phosphor plate, flat panel detector or CdTe detector. The examination can be performed in static 2D (named radiography), in real time 2D (fluoroscopy), or in 3D after image reconstruction ( co ...
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Punch Press
A punch press is a type of machine press used to cut holes in material. It can be small and manually operated and hold one simple die set, or be very large, CNC operated, with a multi-station turret and hold a much larger and complex die set. Description Punch presses are large machines with either a 'C' type frame, or a 'portal' (bridge) type frame. The ''C'' type has the hydraulic ram at the top foremost part, whereas the portal frame is much akin to a complete circle with the ram being centered within the frame to stop frame deflection or distortion. C type presses have a bed plate which is used to lock the die bottom bolster. For locking the die, T-bolts are used and so this plate contains T-slots into which T-bolts are slid in. These slots are placed diagonally and with a slot horizontal to the longer side of the plate, is the general practice. These slots run up to a central hole made in the plate, the hole being large enough to accommodate another bush with a hole, the ho ...
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Quenching
In materials science, quenching is the rapid cooling of a workpiece in water, oil, polymer, air, or other fluids to obtain certain material properties. A type of heat treating, quenching prevents undesired low-temperature processes, such as phase transformations, from occurring. It does this by reducing the window of time during which these undesired reactions are both thermodynamically favorable, and kinetically accessible; for instance, quenching can reduce the crystal grain size of both metallic and plastic materials, increasing their hardness. In metallurgy, quenching is most commonly used to harden steel by inducing a martensite transformation, where the steel must be rapidly cooled through its eutectoid point, the temperature at which austenite becomes unstable. In steel alloyed with metals such as nickel and manganese, the eutectoid temperature becomes much lower, but the kinetic barriers to phase transformation remain the same. This allows quenching to start at a lo ...
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Vacuum
A vacuum is a space devoid of matter. The word is derived from the Latin adjective ''vacuus'' for "vacant" or "void". An approximation to such vacuum is a region with a gaseous pressure much less than atmospheric pressure. Physicists often discuss ideal test results that would occur in a ''perfect'' vacuum, which they sometimes simply call "vacuum" or free space, and use the term partial vacuum to refer to an actual imperfect vacuum as one might have in a laboratory or in space. In engineering and applied physics on the other hand, vacuum refers to any space in which the pressure is considerably lower than atmospheric pressure. The Latin term ''in vacuo'' is used to describe an object that is surrounded by a vacuum. The ''quality'' of a partial vacuum refers to how closely it approaches a perfect vacuum. Other things equal, lower gas pressure means higher-quality vacuum. For example, a typical vacuum cleaner produces enough suction to reduce air pressure by around 20%. But hig ...
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