acma – fraunhofer technology day resource efficiency...

© Fraunhofer IWU

Prof. Neugebauer

ACMA – Fraunhofer Technology Day

New Delhi, September 8, 2011

R. Neugebauer, F. Treppe, S. Schiller

IWU Fraunhofer Chemnitz, Germany

Resource Efficient Manufacturing of Powertrain Components

Resource Efficiency in Car Manufacturing

© Fraunhofer IWU

Prof. Neugebauer

Archivierungsangaben

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Agenda Resource Efficiency in Car Manufacturing

Part 1: Resource Efficiency in Car Manufacturing (Sven Schiller)

� Lightweight Car Powertrain

� From Component to Innovation

� Resource Efficient Manufacturing by optimized Component Design

� Lightweight Conrod

� Resource Efficient Manufacturing by Innovative Technologies

� Gear Rolling of Single Gears and Gear Shafts

� Spin Extrusion of Hollow Parts and Inner Profiles

� Extrusion of Gear Shaft Preforms

� Summary

Part 2: Resource Efficiency in Car Manufacturing (Frank Treppe)

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Prof. Neugebauer


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Applied Research driven by Industry and Product Specifications

CamshaftCamshaftCamshaftCamshaft

� HydroformingHydroformingHydroformingHydroforming

� GrindingGrindingGrindingGrinding

Gear shaftsGear shaftsGear shaftsGear shafts

� Cross wedge rollingCross wedge rollingCross wedge rollingCross wedge rolling

� Spin extrusionSpin extrusionSpin extrusionSpin extrusion

� Axial formingAxial formingAxial formingAxial forming

Propeller shaftsPropeller shaftsPropeller shaftsPropeller shafts

� Spin extrusionSpin extrusionSpin extrusionSpin extrusion

� Flow formingFlow formingFlow formingFlow forming

GearsGearsGearsGears

� Cross rollingCross rollingCross rollingCross rolling

ConrodConrodConrodConrod

� PrecisionPrecisionPrecisionPrecision----forging forging forging forging

� low-energy engine- conrod (weight -20 %)- camshaft (weight -20 %)

�� lightweight gearing (gear rolling)- process time: - 30 %- material use: - 30 %

Light Weight Car Powertrain

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Prof. Neugebauer


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From Component to Innovation

Objectives:

� minimization of material effort

� minimization of production costs

� minimization of cycle time

� increase of component characteristics

Approaches:

� optimization of current component design

� optimizations of current process chains

� using innovative technologies

� using new materials for light weight prod.

■ technical drawing

■ component requirements

■ process chain analysis

1 2

■ calculation / dimension of innovative process chain

■ work piece redesign

■ CAE of all tools and addendum for each process

■ FE simulations / virtual process optimization, tooling

■ fabrication of aprototype series

■ quality measurements / workpiece studies / fatigue tests

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3 4

5

■ implementation into serial production

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Prof. Neugebauer


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Solid Conrod

Precision forged conrod

weight: 325 g (-20 %)savings: 0,83 kg mass

Objectives for new Camshaft Concepts:

- weight reduction

- material saving

- shortened process chain

��

Lightweight Camshaft

� Analysis of current process and component requirements� new component design (reduction of final weight)� new process design

1. Basic component:weight: 408 g

2. Component development:

3. Final component:

��

Precision Forged Conrod – Innovative Component Design

Resource Efficient Manufacturing by optimized Component Design

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Prof. Neugebauer


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blank Forge rolling orCross wedge rolling

Flattening Preforging

punching,deburring, hot calibrating

Finish forging


Precision Forged Conrod – Process chain

Sizing tool combining clipping

and piercing

qualitycontrol

cutting of a billetfrom the bar

inductiveheating

PreformingCross Wedge Rolling(core competency IWU)

Forging Process

- flattening

- base forming

- final forming

(core competency IWU)

controlledcooling

thermal treatment

Cutting(punching – deburring – calibration)

within one complex tool system

Process Chain

kritisch

grenzwertig

sicher

kritisch

grenzwertig

sicher

insufficient

critical

reliable

Component design andsimulation

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Prof. Neugebauer


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Component with high endurance strengths at minimum weightCompliance with industrial standards for the respective motor (59 kW) No loss of Product PerformanceSuccessful engine tests with new conrodsSuccessful tests in car Mass reduction of approx. 83 g per conrodReduction of billet mass and decrease of forging part cost by 0,18 €Less accelerated mass in the car - secondary effect on crank shaft designReduction of moment of inertia of crank drive Reduction of fuel usage and CO2 emission

Precision Forged Conrod – Results


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Prof. Neugebauer


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FEM-Simulation

Steps to form a control arm

Calculation Tool Design

Mass Distribution by Cross Wedge Rolling Technology


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Prof. Neugebauer


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Solid Gear shaft

HollowGear shaft weight: 1450 g (-51 %)

savings: 1500 kg mass

Objectives for new Camshaft Concepts:

- significant weight reduction

- material saving

- shortened process chain

��

Lightweight Gearshaft

� Analysis of current process and component requirements� new component design (hollow shaft)� new process design using innovative technologies

Resource Efficient Manufacturing by use of Innovative Technologies

1. Basic component:weight: 2950 g

2. Component development:

3. Final component:

��

Formed hollow shaft – Innovative Component Design and Process chain

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Prof. Neugebauer


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Extrusion or Spin Extrusion Gear Rolling and Deburring

Cutting and Deep DrillingRaw part

2

Gear Hobbing and Deburring

Grinding Swaging

3

4 7

Case Hardening

5

1

Shot Peening of the Gear

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Gear Shaft - Conventional Process Chain

Gear Shaft - Innovative Process Chain


Minimized raw part (+ induction heating)

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Prof. Neugebauer


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Extrusion/ForgingRaw Part Gear Hobbing

21 3

Heat Treatment Finishing

54

Single Gear - Conventional Process Chain

Single Gear - Innovative Process Chain

Shot Peening

5

Extrusion/ForgingRaw Part Gear Rolling

21 3

Heat Treatment Finishing

54


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Prof. Neugebauer


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Forming of hollow shafts – Innovative Technologies

Spin Extrusion or Extrusion

Spin extrusion Extrusion


RotationsachsenelektromechanischeLinearachsen

hydraulischeLinearachsen

RotationsachsenelektromechanischeLinearachsen

hydraulischeLinearachsen

Rotation Axis Elektromechani-cal Linear Axis

Hydraul. Linear Axis

3

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Prof. Neugebauer


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� Efficient material utilisation by the forming process

� Short process cycles (up to 50% of deep drilling, depending on the shaft geometry)

� Forming possibility of length-diameter ratios of L : d < 15

� Feasibility of forming high strength steels, e.g. titanium alloys

� Feasibility of forming inner profiles

� Low forming forces because of incremental forming

� Small machine dimensions

Reference Components: Different Inside Contours with Constant Area Section

Resource Efficient Manufacturing by Process Chain Optimization

Forming of hollow shafts – Innovative Technologies

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Prof. Neugebauer


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Forming of hollow shafts – Innovative Technology Gear RollingGear Rolling

4

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Prof. Neugebauer


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� Component clamping

� Initial rolling

� Penetration with changes

of direction

� Calibrating

� Component output


Gear Rolling – Forming Process

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Prof. Neugebauer


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� Tool calculation

� Material flow

� Process parameters


Gear Rolling – Simulation

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Prof. Neugebauer


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� Short process cycles (up to 50% of gear hobbing, depending on the gear geometry)

� Material saving by forming process

(no chips, initial work piece diameter for rolling < initial work piece diameter for hobbing)

� Low forming forces because of incremental forming (small contact area between gear and tools)

� Rolling of narrow located gears on shafts (no joining of gears on the shaft necessary)

� Gearbox minimization

Narrow located gears on shafts


Gear Rolling – Advantages concerning Machine

Quelle: Esea gmbh

Minimization of Transmission Size

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Prof. Neugebauer


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� Strain hardened surface layer (for low loaded components, elimination of hardening)

� Contour related and not cutted material fibre

� Excellent contour stability after case hardening

� Increased tooth root strengths and flank load capacity compared to cutted gears

� Excellent surface roughness after rolling (Ra= 0,3- 0,5µm; Rz= 1,9- 3µm)

Case hardening steel


Gear Rolling – Advantages concerning Component

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Prof. Neugebauer


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� Parameters of shown work pieces

� Module: 2 … 4 [mm]� Pressure angle: 16 … 24 [°]� Tooth height: 5 … 11 [mm] � Helix angle: 12 … 34 [°] � Tooth height coefficient: up to 2.7� Quality (DIN3962): 8 … 11 (pregearing)

6 / 7 (finished) � Materials: case hardening steel,

heat treated steels


Gear Rolling – Single Gears

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Prof. Neugebauer


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■ Reverse gear shaft ■ Hollow drive shaft

■ Hollow drive shaft ■ Reverse gear shaft


Gear Rolling – Shafts

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Prof. Neugebauer


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� Worms

� Pinions

� Threads

� Drill bits

� Rotor profiles


Forming of Special Profiles

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Prof. Neugebauer


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Summary

Core Competences in Bulk Metal Forming

� Cold rolling of gears and special profiles

� Hot forming of shafts by spin extrusion/extrusion

� Precision forging

� Material and Component Testing

� Component and Process Design, Simulation

Equipment

� Two rolling machines (cross rolling with 2/3 tools)

� Different Hydraulic Presses

� Lab for metallographic investigations

� FZG-torque change device (load capacity test gears)

� Pulsator test bench for gear/shaft tooth root strength analyses

� ZEISS gear measurement machine (acc. DIN 3960 / 3962)

� Simulation software: Forge 2009, Simufact

� 4 engineers, 3 student assistants, 1 technician

Project cooperation (Industry, public research)

� Research from development studies (component and process optimization) to the serial production

© Fraunhofer IWU

Prof. Neugebauer


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Thank you very much for your attention.

Contact:

Frank Treppe: [email protected]

Sven Schiller: [email protected]

© Fraunhofer IWU

Prof. Neugebauer


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pressurerolls

work piece

toolsegment

pressure surges

compensationplate

rollcage

outer ring

www.hmp.de


Swaging and Axial Forming

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