FFI Sustainable gear transmission realization

Project time: 2009 – 2012

Budget: 24 000 000 SEK

Funding: FFI – Strategic Vehicle Research and Innovation

Gear transmission products are strategically important key components in powertrains produced by the Swedish automotive industry

Roughly on fifth of the global production of transmission products for heavy vehicles takes place in Sweden. To meet the increasing environmental and sustainability demands, the vision with a year 2025 perspective is 30% stronger and lighter automotive gearboxes with near 100% transfer efficiencies using environmentally adapted lubricants and coatings. This requires robust design and manufacturing processes. Demands for low cost, environmental impact and energy consumption are climbing and the project targeted these by adopting a holistic approach considering all critical factors in gear manufacturing. Accordingly, the project was organized in six workpackages:
 WP1 Project coordination and result dissemination
 WP2 Gear service life efficiency
 WP3 Gear materials
 WP4 Robust design and manufacturing
 WP5 Cutting tools
 WP6 Process planning
Important results obtained are: Gear flanks manufactured using either gear honing or green-shaving are preferable to grinding with respect to running-in and static load carrying capacity. Polar machinability diagrams can be used to understand the variations in machinability of case hardening steel with different microstructures. The variation in surface topography inherent in the manufacturing method is an important factor for the contact condition in the early life of gears. A 3-component  dynamometer system for hobbing has been developed and is ready for testing  in production machine tools. The main wear mechanisms observed during the experiments with the developed single tooth milling (STM) method were crater and flank wear on the primary and secondary cutting edge, respectively. Experimental results showed that the part of hardness on a commercial cutting insert with a TiAlN coating, boosted by the compressive residual stress, was clearly lower at the edge than on a plane surface. Material transfer experiments showed that at high sliding speed the tool coatings failed due to lacking mechanical support, sometimes because the generated heat caused thermal softening of the substrate. AlCrN were shown to protect slightly better against thermal softening than traditional TiN. Design of experiments (DoF) is shown to be a proper method capable of examining the complex process of press quenching. DoF in combination with Monte Carlo simulation is one way to support process planning regarding deeper process knowledge and proper tolerancing.

Participating researcher(s)

Partners

Share

Similar projects

Streamlined Modeling and Decision Support for Fact-based Production Development (StreaMod)

The integration of data management systems, simulation software and optimization algorithms have been shown to increase throughput in existing production but also allow expanded use of virtual tools in the preparation phases. This in turn leads to shorter development times for new production systems and products. The project has also contributed to greater understanding and concrete improvements in the processes of collecting and assure the quality of production data. This in turn increases the quality in both simulations and direct data-driven analyzes.

2013 – 2017

Dense-Arc joining of hybrid thermoplastic composite-metal structures (DENSARC)

The aim with the project is to test a new method to join thermoplastic composite to metal in a lap joint by using a focused TIG arc, as a heat source, to heat the metal side just enough so that the composite melts and join to the metal. The method gives single sided access, no need for additional filler material and makes invisible joints possible. The objective is to have a joining method that is robust, gives high productivity and high quality as well as cost advantages.

2012 – 2013

Virtual PaintShop – Simulation of Oven Curing

The paintshop is often a bottleneck in production and the processes are fine-tuned based on testing on numerous prototypes. To meet the future demands there is a great need to improve the product preparation process. The aim is to develop methods, techniques and software, and supporting measurement methodology, for simulation of paint curing in IR and convective ovens. The goal is to assist the industry to further develop and optimize their surface treatment to be more energy and cost efficient; to have a shorter lead time in product development; and to give a higher product quality.

2016 – 2019

Virtual PaintShop – Simulation of Oven Curing

Sustainable Manufacture of Future Engine Components

The project has addressed challenges in casting and realisation of new cast irons with improved properties and machinability, decision making regarding manufacturing strategies and machinability of materials. Silicon-alloyed compacted graphite iron (CGI) has been demonstrated av new alternative for future engine components. New simulation technique for assessing manufacturing strategies has been introduced. Generic know ledge has been developed w hen it concerns w ork material machinability w ith specific reference to combined materials in advanced components.

2012 – 2015

Emerging digital technologies and their applicability as picking support in materials handling

In material handling processes, such as kitting and sequencing, which are used in the automotive industry to supply the assembly with a wide and growing range of component variants, the picking information system is central design aspect. Given the developments in digitization, the purpose of this concept study is to evaluate the potential of digital technology to support materials handling work in production systems.

2017 – 2017

Sintered parts with high static loading capacity

The project has confirmed the hypothesis that tailoring of the tempering is a functioning means of making PM steel sustainable towards high static loading in potential automotive applications. The project has also developed further understanding about mechanisms that could be responsible for static loading sensitivity with respect to creep/relaxation at slightly elevated temperature. The results relate to sustainable manufacturing processes, the basis being that powder compaction and sintering is an energy efficient way with high raw materials utilization.

2012 – 2013

Automotive components from renewable resources with good barrier properties and tailored biodegradability, for interior applications

Our hypothesis is that advanced, lightweight, multi-layer-structured composites with good barrier properties and tailored biodegradability can be produced by combining bio-based thermoplastic with special additives and pulp fiber mats. This material is free from fossil raw materials, sustainable, fire and impact-resistant and suitable for interior components in vehicles.

2012 – 2013

PADOK – Study Visit to India 2016

With globalization and other megatrends as demographic changes and climate change, more knowledge is needed regarding production in an international perspective. PADOK Study Visit in India 2016 have given an increased knowledge regarding how production is conducted in India, some of the challenges producing companies in that region is facing and how Swedish companies interested in investing in production in India could act to establish themselves in the region.

2016 – 2016

Geometry optimized adhesive joining for sustainable production

"Geometry Optimised adhesive joining for sustainable production” in Swedish (Geometri Optimerad LimFogning för hållbar produktion, "GOLF") is a project within the Swedish research program FFI for Sustainable production. It has as its mission to develop technology and methods to get the right amount of adhesive on the right place. The drivers behind this are the overall strive to decrease weight in vehicles and moving machines to minimize the amount of CO2 in the atmosphere.

2013 – 2015

Compact and energy efficient transmissions – control and prediction of functional surface behavior

The overall objective of the project was to: • Develop simulation methodology for drive simulation of transmissions with given shape, surface topography and surface structure, - for more robust and better prediction of the efficiency and life of gear contacts in gearboxes. • Through experimental evaluation and characterization, support and verify the developed simulation technology • Through experimental evaluation and characterization, further verifying the potential of using the correct surface texture, e.g. honing, and right-handed gear in heavy-duty transmissions.

2016 – 2018