project idea catalogue final...companies, leasing, large fleets and traffic/transportation projects...

PROJECT IDEA CATALOGUE

EUREKA Umbrella

PRO-FACTORY

Brokerage Event Gothenburg

May 5th-6th 2008

Manufacturing in the Automotive Industry

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Virtual manufacturing and IT-related project ideas 1. 3D Interaction in Design and production planning. 2. Advanced Driver Risk and Mechanical Profiling solution including Real‐Time Alerts on

Accidents, Monitoring of Fuel Consumption and Air Pollution – for OEMs, Insurance Companies, Leasing, Large Fleets and Traffic/Transportation Projects

3. The Digital Factory Warehouse Sheet metal forming and other sheet metal project ideas 4. Coil design and manufacturing in Magnetic Pulse forming applications 5. Electrohydraulic sheet metal forming 6. Electromagnetic pulse forming to make functional sheet metal surfaces 7. Hot Stamping with Direct Resistive Heating 8. Lightweight & high-strength structural parts and component 9. Magnetic Pulse Forming of Automotive Parts from Aluminium sheets 10. Titanium and Magnesium forming for structural parts. Surface project ideas 11. Competitive Finishing Machining 12. Development of a scratch resistant coating using a molecular self assembly nano-technology 13. Measurement and modeling of surface appearance in automotive industry 14. Recycling of metallised plastics. 15. Smart visual surfaces –to measure the immeasurable - feelSURF, 16. Surface shielding or screening 016. 3D Surface inspection Laser processing project ideas 17. Functional gradual materials for automotive parts with thermal barrier functions. 18. Geometric variation prediction in automotive assembling 19. Laser decoating of break tubes for automotive industry 20. Reduced Friction in Power Train Through Laser Surface Texturing (LST) 21. Laser Welding of Small Diameter Steel Tubes 22. Painted body repair, correction of micro-embedded particles. Products, equipment, systems project ideas 23. Adaptive Rear Combination Lamp with L.E.D. and with ambient light and soiling sensor for vehicle 24. APAC - Advanced Production of Automotive Components 25. Central-controlled New Style Intelligent Service Set 26. Electromagnetic pulse joining of cables 27. European benchmark study of production efficiency at shop-floor level 28. Lightweight Grippers and Fixtures 29. Manufacturing Life-cycle Management (MLM) for full Change Impact Evaluation 30. New generation interior lighting with LED instead of conventional incandescent bulb and

fluorescent for vehicle 31. Study of recycled painted plastic and/or chrome-plated parts using supercritical C02

technologies 32. Vehicle independent electric transmission architecture 33. Welding of dissimilar sheet materials, electromagnetic pulse welding 34. Hybrid Electric Transmission for Light Duty Vehicles

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Project ideas Virtual manufacturing and

IT-related ideas

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PRO-FACTORY Project Idea Form

> Title 3D Interaction in Design and production planning. > Describe your project idea

The goal of the project is to develop a full color multi view 3D goggle free table top display, built on holographic principles and provided with a real time interaction system. It is supported by ordinary PCs running CAD and Multimedia presentation software. The system will be utilized for testing applications and as demonstrator in product development, process planning at the participating companies. It will also be tested for training and education purposes. The feedback received in these tests and demonstrations will be implemented into the supporting software platform in order to fit it to the industrial needs.

In the first phase of the project the research will focus on the development of an efficient manufacturing technique for the fundamental optical element of the display table – the high quality full colour holographic element. With that goal achieved, the research will concentrate on development, adaption and evaluation of the multi view display in practical tests with industry and research partners. Two systems will also be developed for a virtually co-located meeting environment utilizing high speed internet. The concept of this project has already been demonstrated as a monochrome (black – red) display and it has created a paradigm shift by bringing virtual models out to reality instead of having people going into virtual world. People can sit around the table and without glasses see the presented model in 3D on the table. They can discuss and interact and at the same time have eye contact and see mimics and gestures of each other, see Figure 1. At the same time they can make changes to the model, interrogate it for more detailed information and get related information from the data base.

> Please explain briefly your expertise Optics and holography, Software design and application development for design and manufacturing, information and activity modelling, solid modelling.

> Explain what kind of partner/expertise you are looking for Partners that can contribute application feedback and testing of new principles for interaction in design, production and process planning. Partners from cognitive and perception science for contributing 3D table design requirements and evaluation. Contact information

Full name Torsten Kjellberg, Lars Mattsson

Email address [email protected], [email protected]

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mailto:[email protected]

Organisation name KTH, Royal Institute of technology, IIP

Address Brinellv 66

City Stockholm Zip SE 100 44

Country Sweden

Tel. +4687909069, +4687909175

Fax. +468210851 Workshop Priority (Please select one or more from the list below) D Kind of partner expected

(please select one or more from the list below) I, R, C Workshop Priorities:

- A: Surfaces in automotive applications - B: Laser processing in automotive manufacturing - C: Sheet metal forming for automotive parts - D: Virtual tools in manufacturing

Kind of partner expected:

- I: Industry - R: RTD&I (Research, Training, Development and Innovation) - C: Clients & Users - O: Others

Latest date for proposals

2008-04-15 Please send to [email protected] PRO-FACTORY Project Idea

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PRO‐FACTORY Project Idea Form

> Title Advanced Driver Risk and Mechanical Profiling solution including Real‐Time Alerts on Accidents, Monitoring of Fuel Consumption and Air Polution – for OEMs, Insurance Companies, Leasing, Large Fleets and Traffic/Transportation Projects > Describe your project idea Traffilog would like to provide an advanced Driver Risk and Mechanical Profiling solution that includes:

• Profiling of Drivers Behaviour per Trip • Driver Risk Profiling • Real‐Time Alerts on Accidents – without any action of the Driver (he could be

unconscious) • Mechanical Profiling of the Vehicle • Profiling of the Driver’s Mechanical Driving Skills • Monitoring of Fuel Consumption per Driver and/or Vehicle • Monitoring of Air Polution and CO2 Emission • Real‐Time Alerts on Fuel theft and Extended Air pollution

> Please explain briefly your expertise Established in 2003, Traffilog has developed a web based, technologically innovative solution to better administer fleets. The Traffilog solution focuses on assisting organizations and managers significantly reduce fleet running costs. In this ‘information rich’ era which we live in, the question is not how much we know, but rather what we do with the knowledge. The Traffilog solution has the advanced ability to filter relevant and important data out of the mass of information it receives, thereby providing answers to relevant questions and allowing for cost reduction and improved efficiency of working processes. Traffilog goes ahead of other LBS solutions and offer a product that add value beyond the regular Location‐Based Real‐Time Fleet Management and Track & Trace solutions offered by other companies on the market today. We have developed a unique solution that responds to mobile asset management requirements at all corporate levels. Our solution includes: A) Advance fleet management ‐ vehicle tracking with geo‐fencing for both vehicles and personnel – with routing, replays, maps, interface for SVR and more. B) Risk and Mechanical Driver Profiling – Profiling of driver behaviour and driver mechanical skills, based on G‐sensor (accelerometer) data and CANBUS/OBDII diagnostics data, analyzed by advanced algorithms developed together with the leading Israeli technical university Technion. C) Real‐Time Remote CAN/OBD diagnostics, full reading of all CAN data, management of fuel theft and consumption, load temperature and additional features. > Explain what kind of partner/expertise you are looking for With a vision to become an integral part of all vehicles, the Traffilog solution is well on its way to becoming a standard safety feature; (just like airbags and ABS brakes – can easily be removed), installed by the manufacturer, in all vehicles. Moreover, as they act as an additional safeguard for both the driver and vehicle the Traffilog products have come to justify a reduction in insurance costs. Traffilog is looking for partners who has a local market reach and are interested in the development of a system that is suitable, not only for the Heavy Vehicle market which is

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Traffilog’s main market today, but rather for the large consumer/personal vehicle market. Relevant partners could be within: OEMs Insurance Companies Vehicle Emergency Service Providers Tier 1/2/3 AVL/SVR Providers National Traffic/Road Safety Projects National Infrastructures Large Fleet Companies Integrators and Distributors with reach of Large Fleets And any other interested company...

Contact information

Full name David Lexner

Email address [email protected]

Organisation name Traffilog Ltd.

Address 10 HaAmal St., Park Afeq

City Rosh Haayin Zip 48092

Country ISRAEL

Tel. +972‐3‐9009500

Fax. +972‐3‐9012593

Workshop Priority (Please select one or more from the list below)

Kind of partner expected (please select one or more from the list below)

Workshop Priorities:




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> Title

The Digital Factory Warehouse > Describe your project idea Project Goal and idea. The goal of the project is to develop principles, system architecture and implementation guidelines for storing models of manufacturing resources and their processes in DB in a neutral format. The resource and process models should capture relevant information for all of planning, manufacturing system design and manufacturing applications

The ultimate goal is to provide industry with a digital warehouse of manufacturing resource models in a neutral format, to make them fast and effective in building and running manufacturing lines and systems. By building digital factory models fast and accurate, and in which all relevant aspects of manufacturability, produced quality etc can be evaluated and secured beforehand; it will be possible to achieve fast installations or reconfigurations and ramp-up of production with high overall-equipment-efficiency. It will be an important base for continuous runtime improvement and adaptation to customer requirements and order portfolio. The digital factory model will be a support tool from early development throughout years of operations and redesign. It will be a tool for solving all types of problems, to secure manufacturing system availability.

> Please explain briefly your expertise Information and activity modelling for manufacturing needs and applications - STEP standards as AP 239 PLCS, AP 214 Automotive, AP 224 Features, AP 240 proscess planning, STEP NC AP 238 and 14649 and ISO 13399 for small tools – Solid modelling – concept modelling.

> Explain what kind of partner/expertise you are looking for Concept modelling in a computer interpretable formats. Software applications for planning, manufacturing system design, manufacturing monitoring, manufacturing simulation and analysis.

Contact information

Full name Torsten Kjellberg, Gunilla Sivard

Email address [email protected], [email protected]

Organisation name KTH, Royal institute of technology

Address Brinellv 66

City Stockholm Zip SE 100 44

Country Sweden

Tel. +4687909069, +46707871615

Fax. +468210851

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Workshop Priority (Please select one or more from the list below) D Kind of partner expected







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Project ideas

Sheet metal forming and other sheet metal projects

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> Title Coil design and manufacturing in Magnetic Pulse forming applications

> Describe your project idea Magnetic Pulse (MP) forming (cutting, stamping, welding etc) is a very interesting emerging field for high speed deformation of materials. A research group at Lund University has developed a new technology to design and manufacture electromagnetic coils, suitable for example magnetic pulse forming. Examples of interesting project ideas are: Hybrid forming (Induction heating in the same tool with the same coil as the MP), with large flexibility, high efficiency and high strength coil design. 3-D surface coils or Non-closed loop coils e.g. straight lines, haft circles etc. Coil design with minimized inductance, detailed magnetic field pattern and large heat conductivity. > Please explain briefly your expertise Iprod has a vast experience of simulation of magnetic systems in general and specifically MP and induction heating. Iprod has also developed a new family of Soft Magnetic Composites (SM2C) namely Soft Magnetic Mouldable Composites that lends itself perfectly for inductor design to MP- and induction heating applications. The production technique called RotoCast, allows for new design concepts. New coil geometries can easily be realised that, according to simulations, can significantly improve the efficiency of forming coils. > Explain what kind of partner/expertise you are looking for An industrial partner with challenging applications in the sheet metal industry. (New materials, e.g. magnesium, and advanced forming processes.) Also a company with MP system expertise and MP system products.

Contact information

Full name Tord Cedell


Organisation name Division of Production and Materials Engineering (IProd), LTH

Address Ole Römers väg 1

City Lund Zip S-221 00

Country Sweden

Tel. +46 709 752221

Fax.

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Workshop Priority (Please select one or more from the list below) C Kind of partner expected

(please select one or more from the list below) I Workshop Priorities:






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PRO-FACTORY Project Idea

> Title

Electrohydraulic sheet metal forming for prototypes or low volume production

> Describe your project idea If a controlled amount of electric energy are stored in a capacitor bank and subsequently is

released into a spark gap a transformation occurs. The electric energy is ionizes in the spark gap and a small explosion takes place. Shock waves emanating from the explosion move outward in all directions and can be controlled to produce deformation in a sheet metal. The efficiency of the energy conversations is improved by submerging the spark discharge in a liquid, such as water. A controlled sheet metal deformation produced by this process is called electrohydraulic forming (EHF). A schematic description of the process is shown in figure 1 and some of the prototypes that have been made lately are found in figure 2.

Figure 1 A schematic description of electrohydraulic forming process.

Figure 2 Some parts that have been produced by electrohydraulic forming process.

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From experiments following advantages with electrohydraulic forming (EHF) has been

recognised: • Only one die (rapid tooling) • Low cost tooling (Composites, Al-alloys etc) • No big hydraulic press (low investment) • A high velocity (strain-rate) process • Discharge design provides complex shape at high velocity • Increase formability • Less wrinkles • High flexibility • Low energy consumption • Material’s electrical conductivity isn’t a key parameter as it is in electromagnetic

forming This project idea concerns analysis of the potential of using electrohydraulic system

(EHF) for low volume production of sheet metal components. The specific objectives for this project proposal is as follows:

• Develop a design methodology for EHF concerns process design and optimization • Standardization / Particularization of the process related to the components’

geometries • Numerical simulations of the process • Comparison studies against other low volume production methods

o Sheet hydroforming - Quintus press o Incremental forming o Conventional deep drawing

• Tooling requirements o Stress, loads and deflections in the tools o Performance

• Low cost tooling o Composite tools o Composite tools with spray coated metallic surface o Kirkzite/Al tools o Non-hardened steel tools o Concrete composite tools

• Cost analysis for implementation for low volume production of sheet metal parts > Please explain briefly your expertise

Svensk Verktygsteknik is a Swedish based research & development institute in the field of manufacturing processes. The key role is to through application research implement new technologies and productions processes mainly for automotive manufacturers and tier 1-2 suppliers around the world. Through our combination of RTD-projects and commercial engineering projects we bring the latest technology to our customers and remain updated with the needs of the manufacturing industry. This makes us a competitive partner assisting our customers in their effort to develop and maintain world class performance. To be able to support our customers in the best way possible, we cooperate with companies, institutes and universities in Europe and the US, thus accessing leading researchers and modern experimental equipment.

For pilot production initiative to analyse the process we have an experimental electrohydraulic system in our lab. In this project proposal we collaborate with a couple of R&D Institutes in Europe and the former east states as well as with European industrial system suppliers.

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> Explain what kind of partner/expertise you are looking for

The preferable partner we look for to collaborate in this project proposal will come from either an automotive manufacturer or a large component manufacturer to the automotive industry.

Contact information

Full name Roger Andersson


Organisation name Svensk Verktygsteknik

Address Aurorum 6

City Luleå Zip SE-977 75

Country Sweden

Tel. +46 920-75917

Fax. +46 920-75955

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(please select one or more from the list below) I, C and O Workshop Priorities:






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> Title

Electromagnetic pulse forming to make functional sheet metal surfaces

> Describe your project idea Electromagnetic pulse manufacturing processes (EMP) is based on the discharge of a

capacitor battery to create a high pulse current under a very short time period through a coil. Large currents run through the coil and take the form of a damped sinus wave. This creates a pulsed magnetic field which induces eddy currents in any conductive materials nearby the coil. The eddy currents induced in the nearby metallic material will be in opposite direction of the primary current and this generates a magnetic force, the Lorentz force, which deforms the material. The whole process is taken less then 100µs, which make it to a high strain-rate forming process. The performance of the process is strongly related to a correct design of the forming coil.

The efficiency and the obtained magnetic force is strongly related to the conductivity of the sheet material so a material with high conductivity like Al-alloys is easier to make complex forming operations then for steel sheet materials. One advantage with the high speed forming process is when the sheet material hits the die surface it is possible to make functional surfaces on the sheet specimen on only one side. With engraved die surfaces it is possible to make almost whatever sheet metal surface that is required or desired. Some examples are shown in figure 1.

Figure 1 Examples of surface embossing of sheet metals achieved by electromagnetic pulse forming. The lower picture show of a single sided sheet metal surface that was made only by using a grinding paper between the sheet metal and tooling die.

This project idea is to develop and analyse functional single-sided surfaces of sheet metals. This can be accomplished by first use laser engraving of the surfaces of sheet metal forming dies and subsequently use electromagnetic pulse forming technology to achieve the

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necessary impact speed of the sheet metal to the die surface to create the functional surface.

When the type of materials and surfaces has been decided then a typical pilot production initiative could look like this:

1. Feasibility analysis the proposed project a. Svensk Verktygsteknik provides more detailed info based on prior

experience/know how. 2. Feasibility yes, then Pilot Production Initiative will start

b. Mutual NDA will be signed to enable free flow of information c. Customer provides drawings and samples d. Svensk Verktygsteknik analyse the drawings and if needed design

modifications to enable EMP process e. Customer agrees on advised modifications f. Customer is responsible for die design and manufacturing g. Svensk Verktygsteknik prepares pilot production set up (laser engraving of

forming dies, electromagnetic coil & tool design, process set-up) h. Svensk Verktygsteknik and the customer share the responsible for coil

manufacturing in agreement of specifications i. Svensk Verktygsteknik conducts the experimental electromagnetic pulse tests

in their system j. Svensk Verktygsteknik conducts required tests (Surface scanning etc) k. Svensk Verktygsteknik provides lab reports l. Svensk Verktygsteknik provides parts to the customer based on specifications

3. Customer conducts all tests needed to verify the technology If the technology has passed all criterions (quality, production rates, and cost etcetera) then next step is to prepare for implementation in the manufacturing process. A general description of this phase could look like this:

1. Customer and the system supplier set up a EMP implementation plan a. First step is to analyse current production set up b. Second step is to define EMP production set up c. Third step is system implementation and training d. Fourth step is the production guidance

> Please explain briefly your expertise


One of our expertise areas is to analyze and implement electromagnetic pulse processes in manufacturing systems for different type of applications. For pilot production initiative to develop and analyse the process we have the state of the art electromagnetic pulse system in our lab. In this field we also collaborate with the best supplier of electromagnetic pulse system in the world; namely Pulsar from Israel.

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> Explain what kind of partner/expertise you are looking for


Contact information




Address Aurorum 6


Country Sweden

Tel. +46 920-75917

Fax. +46 920-75955

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> Title

Hot Stamping with Direct Resistive Heating

> Describe your project idea The project is a new hot stamping and heat treating process for production of ultra high strength structural parts. In this method blank sheet is heated by electric current applied through the workpiece directly within a few seconds without using a furnace or another heat source. Heating and stamping stages are applied synchronously. Difficulties of conventional hot stamping process such as furnace and rapid handling requirements and heat loss during handling are eliminated. A hydraulic press can be converted into a hot stamping unit by installing current heating system with a low cost. We have carried out experimental studies and results are very successful. Investment and production costs, microstructure of finished parts are better than that of conventional furnace heating and hot stamping process. Process is patented US 6.463.779 and US 7.285.761. We have also other international patent applications. Our system is available for demonstration > Please explain briefly your expertise The process is my patented concept. We have a small company and we are carried out experiments of the process . We are using some goverment financial supports for R&D facilities. I am a mechanical engineer and have a number of inventions in several areas. Our website is www.hotforming.com We have also a partner www.inovent.com.tr

> Explain what kind of partner/expertise you are looking for Automotive companies, technical institutes and universities

Contact information

Full name Mehmet Terziakin

Email address [email protected] , [email protected]

Organisation name Metalform Muh. Ltd. Sti.

Address ITU Kosgeb B/1 Maslak

City Istanbul Zip 34147

Country Turkey

Tel. +90 262 678 89 00 , +90 212 542 96 60

Fax. +90 212 542 96 60

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http://www.hotforming.com/

http://www.inovent.com.tr/










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> Title

Lightweight & high-strength structural parts and components.

> Describe your project idea The overall objective of this proposal is to reduce weight of vehicle structures by

developing new and functionally graded material-systems and components with improved mechanical performance. Considering the big challenges in the area of environment protection that we will face in the next few years, the pressure on nearly all industries to use existing resources with optimal efficiency increased enormously. In this context, an essential and fundamental approach for emission reduction is a significant reduction of average fleet weight by lightweight constructions because this directly results in lower driving resistance (air resistance) and, therefore, in a lower fuel consumption per vehicle km. The reduction of emissions is one of the most important issues for the European Union because the baseline trend is that the transport emissions will increase by 41% from 1990 to 2010 according to the green paper of the European Commission (“Towards a European strategy for the security of energy supply”, COM(2000) 769, November 2000).

This project idea is the development of high-performance lightweight structural parts and components from high strength aluminium alloys (from 6000 or 7000 series), which can be locally reinforced by Metal Matrix Composite (MMC) and/or locally polymer foam filled. A significant improvement of mechanical performance and crashworthiness of those parts and reduced weight, at the same time, shall be realized by gradual variations of the mechanical properties, according to existing local requirements (like complex of loads, energy absorption, etc.) of certain structural components. To create new solutions and production methods for such highly-demanding products, the planned research and development work shall be performed in three phases:

1. Design phase: identification and definition of material and component requirements. Here, special regard has to be paid to the mechanical properties in different local regions of the part/component.

2. Manufacturing Phase: the development of material-systems as well as adapted production processes (extrusion, preforming and calibrating processes) are focused during the manufacturing phase. The final step of the described process chain is the forming operation using a process combination of warm/cold hydroforming and electromagnetic forming. A schematic description is shown in figure 1.

3. Validation & Testing Phase: the produced parts shall be investigated and tested regarding the defined functional requirements. Mechanical tests shall be carried out, starting with separated single functions, including corrosive degradation or residual stresses, over complexes of loads up to the evaluation of overall crash performance.

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Figure 1 Possible process chain for manufacturing of functionally graded light weight profiles

This project proposal reaches beyond the state-of-the-art by for example using by adding

reinforcing materials as e.g. fibres or particles to the aluminium base material. This can be achieved by using modified porthole dies in the extrusion process. To further modifying material properties in longitudinal and cross sectional direction then “tailored” billets, consisting of different materials, arranged e.g. in subsequent or coaxial layers, might be used. Instead for making straight extrusions with further forming steps (e.g. profile bending, cutting, etc.) the curved profile extrusion process will be explored to make two or three dimensionally curved profiles. The Hydroforming process will be using both water as well as gas as pressure medium. The advantage with gas is that is possible to heat up the tubular parts in different regions to achieve local increase in formability during to blow forming process. Another unique forming process is based on electromagnetic pulse. The electromagnetic pulse forming process (EMF) is a non-contact forming technology, applicable to materials of high electrical conductivity, like aluminium alloys, and acting within the range of microseconds. The EMF process can be used either as a stand-alone unit or combined with other forming technologies.



One of our expertise areas is to analyze and implement electromagnetic pulse processes in manufacturing systems for different type of applications. For pilot production initiative to

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develop and analyse the process we have the state of the art electromagnetic pulse system in our lab. In this field we also collaborate with the best supplier of electromagnetic pulse system in the world; namely Pulsar from Israel.

In this project proposal we collaborate with several Universities and R&D Institutes around Europe as well as with one of the largest al extrusions companies in the world. > Explain what kind of partner/expertise you are looking for


Contact information




Address Aurorum 6


Country Sweden

Tel. +46 920-75917

Fax. +46 920-75955

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> Title Magnetic Pulse Forming of Automotive Parts from Aluminium sheets.

> Describe your project idea As the trend to reduce car fuel consumption is increasing, new lightweight materials should be used for the fabrication of automobiles. One of the materials that is continuously replacing steel in the car body is Aluminium. One of the problems that needs to be solved when forming automotive parts of Aluminium is it’s lower formability compared to steel. Based on the elongation to failure properties, the formability of Aluminium is <½ that of steel. In order to form automotive parts of sheet Aluminium, new forming processes need to be developed. The magnetic pulse forming (MPF) process is a fast forming process, which provides vast benefits over conventional forming processes. Due to the speed of the process, which accelerates the formed piece to speeds of 200-600m/s, considerable improvement in formability can be achieved. This phenomenon is referred to in the literature as “super-elasticity” The MPF process utilizes high electrical currents which are created by discharging a large amount of electrical energy, stored in stored in capacitors, in a fraction of a second. These currents create strong magnetic fields which accelerate the sheet metal onto a single sided die, in order to form the desired part. MPF works on all conductive materials such as Aluminium, steel and stainless steel. In addition to increasing the metal formability other benefits of the process include the ability to work with a single sided die, reduction in the number of process steps, elimination of surface damage as this is a non-contact process, elimination of lubricant use and the allied post forming cleaning process. > Please explain briefly your expertise Design and manufacture of energy storage units used in electromagnetic pulse forming processes. The expertise includes design of high voltage/ high current systems, design of low inductance systems, insulation for high voltage.

> Explain what kind of partner/expertise you are looking for Seeking:

1. Expert in the design of coils for electro magnetic forming 2. Expert in traditional forming processes 3. Simulation capability of a sheet metal forming process. 4. Automotive end user to specify the demands and requirements for formed sheet metal

parts.

Contact information

Full name Hovav Gilan


Organisation name Pulsar ltd.

Address 4 Faran st.

27


City Yavne Zip 81103

Country Israel

Tel. + 972 544 2191 533

Fax. +972 8 942 7746 Workshop Priority (Please select one or more from the list below) C Kind of partner expected

(please select one or more from the list below) C, R Workshop Priorities:






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> Title Titanium and Magnesium forming for structural parts.

> Describe your project idea Industrialisation of light alloys parts for structural purposes in automotive, aerospace and railway applications Choice of alloys, process conditions and steps and design rules will come into consideration. The tasks to be performed include:

• Selection of representative parts, and their mechanical and working requirements. • Choice of suitable alloys. • Development of forging processes. • Simulation of forging maps and validation of parameters. • Design rules for the light alloys parts to fulfill the required mechanical properties. • Manufacturing of samples. • Definition of heat pre and post treatment. • Definition of specifications of surface treatments. • Functional test of the manufactured part.

> Please explain briefly your expertise The current partners in the project (SME and Technical center) have expertise in the forming of non-ferrous alloys. Simulation of forging processes has also been validated. Metalographic characterisation and mechanical testing of the final parts can also be dealt with. Both have been operating in markets such as automotive, metal goods, railway products, etc. > Explain what kind of partner/expertise you are looking for Industries working in the automotive, aerospace, railway supply chains manufacturing light alloys parts. Technical centers with expertise in the formability of Titanium and Magnesium alloys.

Contact information

Full name Manuel Sánchez de la Asuncion


Organisation name AIMME

Address Avda. Leonardo da Vinci, 38

City Paterna Zip 46980

Country Spain

Tel. + 34 96 131 8559

Fax. +34 96 131 8168

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Workshop Priority (Please select one or more from the list below) C, A, B, D Kind of partner expected

(please select one or more from the list below) I, R Workshop Priorities:






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Project ideas

Surfaces

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> Title Competitive Finishing Machining

> Describe your project idea Fine milling, Grinding, Honing, Lapping, Polishing, Hardening, Coating, ….. the final machining stages of a process chain create much the function of the final product and has a heavy influence of the competitiveness (price). The companies who can quantify the resulting surface integrity (topography, chemistry, stress state, metallography) has a strategic tool to both understand function and to control the machining process. The project will explore possibilities to combine surface integrity measures from various sources to form new “detailed fingerprints” of novel recently standardised 3D topography, residual stress, surface chemistry, material phases. The project will develop the general methodology based on the partners automotive applications. > Please explain briefly your expertise The Functional Surfaces Research Group at Halmstad University has a long history working both on European projects and numreous national projects in the field of Automotive Surface Engineering. Cylinder liner- Gear-, Camshaft-&Roller-, Sheet steel-, Toolsurfaces are examples of applicaions the group has covered. The main expertice is in topography characterisation. The Group in Halmstad has a strong co-operation with The Metal Cutting Research Centre at Chalmers University of Technology in Göteborg where metal cutting, simulation and material science are strong topics. > Explain what kind of partner/expertise you are looking for The proposal is interested to meet partners with own applications where finishing is important, finishing process owners or developer, or parners with experience in topography-, surface chemistry-, surface stress state-, metallography analysis.

Contact information

Full name B.-G. Rosén


Organisation name Halmstad University, Chalmers University

Address Box 823

City Halmstad Zip SE-301 18

Country Sweden

Tel. +46 730335272

Fax.

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Project ideas

Surfaces

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Workshop Priority (Please select one or more from the list below) A Kind of partner expected

(please select one or more from the list below) I, R, C, O Workshop Priorities:






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> Title Development of a scratch resistant coating using a molecular self assembly nano-technology for plastic products. > Describe your project idea The project aims to develop a novel high performance scratch resistant coating technology for plastic pieces at a low cost using an environmental friendly and tailor-made process. These new coated could be applied over the low scratch resistance polymers such as polypropylene (PP), polycarbonate (PC) and ABS. These coated plastics can substitute weighty materials, as metallic or glassy components, and high cost engineering plastic materials. The new coating technology to develop is based on self assembly nanotechnology. > Please explain briefly your expertise Expertise in Plastics, including: 1) Technical Services

- Analysis and testing of plastic materials - Transformation of plastic materials - Technical advice and assistance - Design and development of products - Calibration of measuring and testing equipment - Metrology of parts and components - Environment and recycling

2) Development and improvement of polymer materials - Composites (nano-materials, natural fillers/fibres, active and intelligent materials, etc) - Biodegradable materials - Improvement of the properties of traditional materials

3) Improvement of the transformation processes - (Blown and flat) film and sheet extrusion (mono and multi-layered) - Closed mould transformation techniques at low pressure (infusion and RTM) - Co-injection - Thermoforming and compression techniques at high pressure and temperature

4) Recycling - Recycling of waste for new applications

Increasing the valorisation of the product and ecodesign. > Explain what kind of partner/expertise you are looking for Injections or extrusions of parts made with scratch resistant materials.

- Application sector: automotive, electronics, construction (flooring, work surfaces)

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Contact information

Full name Cristina Del Campo


Organisation name REDITA – Red Tecnológica de Automoción de la Comunidad Valenciana

Address Colón 66

City Valencia Zip 46004

Country Spain

Tel. 0034 961 961 262

Fax. 0034 961 961 260 Workshop Priority (Please select one or more from the list below) A, C Kind of partner expected

(please select one or more from the list below) I, C Workshop Priorities:






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Measurement and modeling of surface appearance in automotive industry

> Describe your project idea The objective is twofold –

1) To develop better measurement tools for assessment of visually attractive surfaces and surface coatings

2) To develop a dedicated visual appearance model based on measurable physical properties of these surfaces with the goal of simulating the optical response imaged into the human eye.

The task will be performed within a suggested time frame of 4 years and will be based on dedicated measurements by scatterometry and the newly presented GRACE light scattering model based on true material properties. > Please explain briefly your expertise 27 years of research on surface characterization, surface structure, light scattering, and optical interaction at surfaces. Development of non-contact measurement tools for rapid surface structure inspection in the micron to sub-nanometre range. Responsible for the development of the GRACE Monte-Carlo model simulating optical scattering in paper structures. Author of the book Introduction to Surface Roughness and Scattering, and more than 120 scientific articles.

Based on 16 years of industrial related research on surface metrology in many different areas the we have found the metrology and modelling of Surface Appearance to be poorly developed, despite the fact that the value added by surface finishing in overall products ranging from e.g. paper, fabric, sheet metal to luxurious consumer products and gemstones is counted in billions of dollars/year just in the United States.

> Explain what kind of partner/expertise you are looking for Automotive industry, paint and surface finish manufacturers, visual perception specialists from cognitive sciences, materials scientists for analysing internal structure of coatings, computer optimization developers.

Contact information

Full name: Lars Mattsson


Organisation name KTH – The Royal Institute of Metrology

Address Industrial Metrology & Optics, Production Engineering

City Stockholm Zip 100 44

Country Sweden

Tel. +46-8-7909175

Fax.

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(please select one or more from the list below) I, C, R Workshop Priorities:




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> Title Recycling of metallised plastics. > Describe your project idea Search for alternative solutions that avoid the non recycling of a plastic part after metal coating.

• Process for separating the metal coat and the base polymer, making it possible to recycle the polymer.

• Laser cladding of metallic powder avoiding the use of Palladium (Pd) (the most pollutant component of the current coating), currently used as base of the metallic coating.

• Development of recycled polymers that can be used as base for metallic coating, making it less important not to recycle the polymer after the coating.

• Development of plastic materials with “metal looking finishing” that look like metal directly after injection, avoiding the phase of metal coating.

> Please explain briefly your expertise Expertise in Plastics: 1) Improvement of the transformation processes:

- (Blown and flat) film and sheet extrusion (mono and multi-layered). - Closed mould transformation techniques at low pressure (infusion and RTM). - Co-injection. - Thermoforming and compression techniques at high pressure and temperature.

2) Recycling: - Recycling of waste for new applications. - Increasing the valorisation of the product and ecodesign.

Expertise in Metal-mechanical technologies: 1) Electrochemical surface treatment of both metallic and polimeric substrates. 2) Corrosion, adhesion and ageing tests of coatings (metallic and paintings). Expertise in Laser and Optical Technologies:: Broad experience on laser materials processing. In this project we could look into different laser processes:

- Laser material removal or cleaning by melting and ablating the coatings. - Laser cladding by melting a powder. - Laser induced electroplating.

> Explain what kind of partner/expertise you are looking for Enterprises interested in using the developed techniques.

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Contact information




Address Colón 66


Country Spain

Tel. 0034 961 961 262

Fax. 0034 961 961 260 Workshop Priority (Please select one or more from the list below) A Kind of partner expected







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> Title feelSURF, Smart visual surfaces –to measure the immeasurable

> Describe your project idea Visual surfaces wether internal or external, has a major impact on the customers opinion and “feeling” for the product as a whole. The companies who can predict customers expected visual- and tactile apprehension of the product based on quantified measures of surface properties like texture, hardness-, Young modulus, and gloss has the strategic tool to integrate desirability into the product in early development phases. The project will develop the general methodology based on the partners’ applications.

> Please explain briefly your expertise The Functional Surfaces Research Group at Halmstad University has a long history working both on European projects and numreous national projects in the field of Automotive Surface Engineering. The main expertice is in topography characterisation. The Group in Halmstad has a strong co-operation with the Industrial Design Group at Jönköping University and covers both quantitatively measures as well as qualitative measures of costomer demands and desires. > Explain what kind of partner/expertise you are looking for The proposal is interested to meet partners with own applications where visual impression is important, finishing process owners or developer, or partners with experience in gloss-, topography-, micro-nano hardness and partners interested in human perception of products.

Contact information

Full name B.-G. Rosén


Organisation name Halmstad University, (Jönköping University)

Address Box 823

City Halmstad Zip SE-301 18

Country Sweden

Tel. +46 730335272

Fax.

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(please select one or more from the list below) I, R, C, O Workshop Priorities:






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> Title Surface shielding or screening. > Describe your project idea Development of materials for surface shielding or screening, in order to avoid electrostatic discharges. Use of nano compounds, conductor polymers, etc.

> Please explain briefly your expertise Expertise in Electrical Technology: 1) Capacities of the Industrial Electrostatics laboratory:

- Advanced electrostatic characterization of materials: charge dissipation, surface or volume resistance, potential decay or return potential analysis, very low current measurements, electric field measurements, measurements under very low humidity (less than 10% at 25ºC).

- Analysis of real dissipative elements in their working conditions: furniture, tools, plastic cases or pieces. This allows the testing of charge dissipation under real conditions with surface treatments, grounding points connections, etc.

- Testing according to several standards - In-situ diagnostic of installations or equipment (charge generation focus, remediation

of electrostatic discharges, resistance measurements, electrostatic charge detection and measurement, etc.)

- Atmospheric electric field measurement - Development of R&D projects based on electrostatic charges applications (electrets

materials, piezoelectric materials from polymer foams, etc.). 2) Capacities of Applied Chemistry Laboratory

- Experience in synthesis of nanoparticles. Procedures to obtain titanium nanoparticles and doped titanium with cobalt nanoparticles.

- Own equipment for nanoparticle characterization: UV, FTIR, and thermogravimetric (TGA).

- Have the means to the following equipment to finish the nanoparticles characterization: scanning electron microscopy (SEM) and X-ray diffraction.

Expertise in Plastics: 1) Development and improvement of polymer materials:

- Composites (nano-materials, natural fillers/fibres, active and intelligent materials, etc).- Biodegradable materials. - Improvement of the properties of traditional materials.

2) Improvement of the transformation processes: - (Blown and flat) film and sheet extrusion (mono and multi-layered). - Closed mould transformation techniques at low pressure (infusion and RTM). - Co-injection. - Thermoforming and compression techniques at high pressure and temperature.

> Explain what kind of partner/expertise you are looking for Suppliers of parts needing screening, displays, or with any electrostatic discharge issue.

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Contact information




Address Colón 66


Country Spain

Tel. 0034 961 961 262








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> Title 3D Surface Inspection

> Describe your project idea We are interested in building automated surface inspection systems for inspectiong surface quality of 3D automotive parts. We are interested in building automated surface inspection systems for on-line inspection of 2D sheet metal and 3D formed metal parts in automotive industry. We seek to find a cost-effective and reliable way to perform all the inspection tasks with minimum operator intervention, with combination of laser and 3D vision techniques. > Please explain briefly your expertise We are a system integrator whose expertise is in building machine vision based automation systems. We are a spin-off from Sabanci University, VPALAB, which has been selected by European Union as a “potential center of expertise”. Our founders have over 25 years of experience in machine vision, especially in surface texture modelling.

> Explain what kind of partner/expertise you are looking for Mechanical/robotics integration, surface inspection technologies

Contact information

Full name Aytul Ercil


Organisation name Vistek Machine Vision and Automation A.S

Address GOSB Teknopark, High Tech Building, 2nd floor, A2, Gebze

City Kocaeli Zip 41480

Country Turkey

Tel. +90 532 362 1922

Fax. +90 262 678 89 06

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Workshop Priority (Please select one or more from the list below) Kind of partner expected

(please select one or more from the list below) Workshop Priorities:






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Project ideas

Laser processing

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> Title Functional gradual materials for automotive parts with thermal barrier functions. > Describe your project idea Laser cladding application for improvement of parts and functionality of “functional gradual materials”. Investigation around the use of new substrate materials, such as plastic materials.

> Please explain briefly your expertise Expertise in Laser and Optical Technologies: Experience in the development of laser cladding applications with very diverse materials. We are able to process metals, ceramics, clagg and combinations of them. The idea should be to look into different combinations of materials, composition, geometry, size, est, in orther to find new applications for this techniques. Expertise in Plastics: 1) Development and improvement of polymer materials

- Composites (nano-materials, natural fillers/fibres, active and intelligent materials, etc) - Biodegradable materials - Improvement of the properties of traditional materials

2) Improvement of the transformation processes - (Blown and flat) film and sheet extrusion (mono and multi-layered) - Closed mould transformation techniques at low pressure (infusion and RTM) - Co-injection - Thermoforming and compression techniques at high pressure and temperature

> Explain what kind of partner/expertise you are looking for Enterprises developing special components for transport applications.

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Contact information




Address Colón 66


Country Spain

Tel. 0034 961 961 262

Fax. 0034 961 961 260 Workshop Priority (Please select one or more from the list below) A, B Kind of partner expected







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> Title

Geometric variation prediction in automotive assembling

> Describe your project idea Automotive parts and BIW structures experience often several assembly stations before

the structure is completed. Each assembly station creates residual stresses that cause geometrical deviation of both parts and structures. These stresses arise either from the clamping or the joining process. The deviation from each assembly station could lead to that the tolerance of the final structure is outside the acceptable level.

If it’s possible to plan the welding assembly design and fabrication process to minimize or control distortion through numerical simulation it can significantly reduce fabrication costs and improve the quality dramatically.

For distortion control, fabrication design via modelling can:

• Eliminate the need for expensive distortion corrections • Reduce machining requirements • Minimize capital equipment cost • Improve quality • Permit pre-machining concepts to be used

Controlling stresses can significantly enhance the structure’s service life. Stress control via modelling can:

• Reduce weight • Maximize fatigue performance • Lead to quality enhancements • Minimize costly service problems

Welding assembly design and fabrication simulation for large-scale assemblies, using a

temperature field on the global structure, is not fast enough to answer the questions of engineers and designers in a timely manner. The time-consuming part of such a welding fabrication simulation is the mechanical simulation. To overcome this limitation, and to avoid the necessity that designers need to deal with nonlinear Finite Element simulations on the full structure, the local-global approach has been developed.

First, inner residual forces due to the heat effects of welding are computed remote from

the global structure, on a local model. The local model is calculated by transient welding simulations of the heat effects of welding, based on the method of Finite Elements. Then, the residual inner forces are extracted and transferred to the global model, and the distortion of the global structure is computed. A schematic description of the Local-Global approach is shown in figure 1 and an optimised spot-weld sequence to minimise distortion is shown in figure 2.

This means that the local-global approach is based on physical observations

• Local phenomenon o High temperature and material non-linearity appear in very small areas

around the welding joint o Plastic strains are concentrated around this small zone

• Global phenomenon o Global distortion of the assembly is due to local plastic strains induced by

the welds

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The behavior of the global structure can be considered to be elastic. The simulation of the welding joints (residual plastic strains and stresses) can therefore be

separated from the global computation (distortion) The advantage of this method against others is the fact that no physics is suppressed and

the residual forces are computed using a sufficient mesh density, which is not possible for large scale structures. Consequently, precise results can be achieved.

Global model:Shell-solid mesh

Local model extraction

Welding path

Local model: Solid mesh

Residual Inner Forces

Local simulation of the welding process accounting for all physical phenomena

Front

Torque

Cross-Car Bumpe

Weld 13

Global Distortion

Projection of inner forces for distortion evaluation

Elastic computation of the global model after projection of inner forces in a sequential order

GM Front-Rail

Figure 1 Description how the Local-Global approach can predict geometrical deviation of a structure

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Figure 2 The Local-Global approach to optimise spot-welding sequence to minimise distortion.

This project idea is through experimental tests and numerical calculations find and optimise the welding sequences, clamping force and position at each assembly stations to minimise the geometric deviations of the final BIW structure.

The experimental test will be done on all type of welding processes that are used (spot-welding, Mig/Tig, Laser, Laser brazing, Hybrid (laser/Tig/Mig), etcetera) to obtain the needed data to calibrate the local weld model. This can be done on several ways but two common methods is:

• through micrographical studies • residual stress and strain measurement simultaneously during the welding process

The second method is a unique method that has been developed during the last years. When all physical data is collected then the numerical simulation software SYSWELD will be used to simulate the local model for the specific welding process. The results from the SYSWELD simulations will subsequently be used as input data to PAM-ASSEMBLY.

The main purpose PAM-ASSEMBLY is to compute the displacements after each step of an assembly sequence and unclamping. With PAM-ASSEMBLY it is possible to optimize, compare and finally select the best possible welding sequence and choice of clamping tools.

The following fabrication conditions can be included in coupled simulations between

SYSWELD and PAM-ASSEMBLY: • Pre-heating • Tandem Welding • Welding with Multiple Sources • Hybrid-Welding

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• Multi-Pass Welding • Contiguous joints fabricated in sections • Post heat treatment of joints • Tack welds • Simulation of contact between components • Elastic distortion compensation when clamping • Unclamping and re-clamping • One-directional stops • External loads (gap closing, compensation distortion) • Self weight

The industrial benefit with this project will be:

• Minimize production cost • Minimize structural weight • Minimize distortions (distortion engineering) • Minimize product risk in the earliest stage of the product development cycle • Master assembly problems • Ascertain the level & distribution of stresses • Control and minimize hardness and grain size in the FZ and HAZ • Avoid cold cracks • Improve the product design • Identify better processes or materials • Meet procedure approvals • Meet product acceptance standards • Implement new production methodologies • Subsequent optimization of the product design and the manufacturing processes • Improved understanding of the effects that lead to distortions and stresses



One of our expertise areas is to analyze joining processes through numerical calculations. For experimental data we have the state of the art metallurgical and measuring system for welding processes in our lab. > Explain what kind of partner/expertise you are looking for


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Contact information




Address Aurorum 6


Country Sweden

Tel. +46 920-75917

Fax. +46 920-75955

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> Title Lazer decoating of break tubes for automotive industry

> Describe your project idea In the process of manufacturing break tubes for automotive industry , decoating of pipe ends before installing fixtures, is a safety critical task because possible leakage of break fuel is catastrophic. Laser technology ,compared to traditional methods like use of abrasives, hazardous solvents etc., is precise, damage free for substrate, and safe to environment .Our research in 2007 resulted in a prototype laser tube decoating machine which is now being tested inhouse for pvf decoating. We plan to improve the technology to allow for decoating of stubborn materials like polyamid etc., to be faster for mass production of break tubes, and for reduced cost to allow for wider use. > Please explain briefly your expertise MSc.in IE from Syracuse Univ.,N.Y.,U.S.A. (1978) , BSc in EE from Ist.Tech.Univ.(1974) . MSc Thesis (1978) titled “microprocessor controlled lathe” is one of the pioneering works done in USA in low cost computer control of machine tools. Since then developed mechatronic systems for industries ranging from textile to metal processing including leather , plastics, electronics and automotive. Since 2005 ,developing laser processing machines for various industries. > Explain what kind of partner/expertise you are looking for . Partners are sought from (but not limited to) Balkan countries, Russian Federation and Israel as client/user to test the technology. Partnership with a local University is also planned.

Contact information

Full name Orhan Tosun


Organisation name BANTBORU Sanayi ve Ticaret A.Ş.

Address GOSB 700.Sok. No.712 , GEBZE

City KOCAELİ Zip 41480

Country TURKEY

Tel. (+90 262) 677 47 13 (Direct), (+90 262) 677 47 00 PBX

Fax. (+90 262) 751 46 37

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Workshop Priority (Please select one or more from the list below) B Kind of partner expected

(please select one or more from the list below) C Workshop Priorities:






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> Title Laser Welding of Small Diameter Steel Tubes

> Describe your project idea Laser beam welding is being successfully used to join metals and alloys like steel, titanium and nickel.. BANTBORU has invested in machine and technology to produce precission small diameter steel tubes (max.10mm.diam) using induction welding and planning to investigate the possible use of laser welding. Besides the other benefits, fusion bonding achieved by laser welding is expected to provide excellent resistance to mechanical and thermal shock.

> Please explain briefly your expertise MSc.in IE from Syracuse Univ.,N.Y.,U.S.A. (1978) , BSc in EE from Ist.Tech.Univ.(1974) . MSc Thesis (1978) titled “microprocessor controlled lathe” is one of the pioneering works done in USA in low cost computer control of machine tools. Since then developed mechatronic systems for industries including leather , plastics, electronics and automotive, ranging from textile to metal processing. In 2007 led the team to develope a “Laser tube decoating machine”for Bantboru which is a major supplier for automotive industry (Patent pending). > Explain what kind of partner/expertise you are looking for BANTBORU will be the user of the technology to be developed but can participate in the development process as well using its R&D background in the field and expertice in laser processing machines. Partners are sought from major European brake tube suppliers and laser welding equipment manufacturers. Partnership with a local University is also planned. Contact information

Full name Orhan Tosun


Organisation name BANTBORU Sanayi ve Ticaret A.Ş.

Address GOSB 700.Sok. No.712 , GEBZE

City KOCAELİ Zip 41480

Country TURKEY

Tel. (+90 262) 677 47 13 (Direct), (+90 262) 677 47 00 PBX

Fax. (+90 262) 751 46 37

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Workshop Priority (Please select one or more from the list below) B Kind of partner expected







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> Title Painted body repair, correction of micro-embedded particles. > Describe your project idea

- Use of laser technology for repairing the painted body, by making micro-cissings - The system would be guided by use of machine vision - Sealing system to be developed: plastic or metallic dust application

> Please explain briefly your expertise Expertise in Laser and Optical Technologies: Experience in laser micro-processing and cleaning of different materials: printing rolls, painted metal plates, etc. We also have experience in the development of special laser systems fitting nonstandard requirements, as could be in this case. Expertise in Metal-mechanical technologies: 1) Defectology of painted metals. 2) Paint application processes. Expertise in Plastics: 1) Development and improvement of polymer materials:

- Composites (nano-materials, natural fillers/fibres, active and intelligent materials, etc).- Biodegradable materials. - Improvement of the properties of traditional materials.



> Explain what kind of partner/expertise you are looking for Car manufacturers.

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Contact information




Address Colón 66


Country Spain

Tel. 0034 961 961 262

Fax. 0034 961 961 260 Workshop Priority (Please select one or more from the list below) A, B Kind of partner expected







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> Title Reduced Friction in Power Train Through Laser Surface Texturing (LST)

> Describe your project idea Laser surface texturing is a method to produce micron-sized dimples on a surface for improving the tribological performance of friction units lubricated with oil. A pulsating laser beam is used to create a large number of micro dimples by a material ablation process. Figure 1. Schematic of LST process and surface after production of micro dimples These dimples generate a hydrodynamic pressure between oil-lubricated parallel sliding surfaces. The micro dimples act as a micro-hydrodynamic bearing with reduced friction as a result. Result from investigations has shown up to 4% reduced fuel consumption with use of laser textured piston rings. It is also reported that the friction decrease with use of laser textured bearings.

Figure 2. Diagram over fuel consumption from experiments carried through at the Department of Mechanical Engineering (Haifa Israel) with series 1, untextured piston rings and series 2, 3 textured piston rings in a cumbsution engine.

Ca 100 μm Depth ca 10 μm

Mirror

Gas

Lens

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The project idea is to further develop the innovative laser technology for reduced friction losses in a combustion engine by LST. Examples of application of LST in a power train for reduced friction.

• Piston rings, liner • Bearings in gearboxes rear axes etc • Crank shaft bearings etc • Other surfaces of interest

Of all practical micro surface patterning methods it seems that LST offers the most promising concept. This is because the laser is extremely fast, clean to the environment and provides excellent control of the shape and size of the micro-dimples, which allows realization of optimum designs. The project will identify and outline parts in the power train where LST can be applied for reduced friction and wear. Scientific and experimental work will be carried through for optimization of the geometry of the LST treated surface for reduced friction and emission of gasses to the environment. Project outline

1. Literature studies to establish the state of the art 2. Numerical analysis for design of optimized dimple geometry 3. Process documentation through laboratory experiments

Development of laser process parameters • Laser density • Defocusing • Pulse frequency • Process gases • Material properties on processed surfaces.

Tribological properties as a function • Dimple geometry (width, depth, density) • Lubrication • Pressure

4. Case studies on applications in power train (bench mark tests in test bench; engine, gearbox etc)

• Piston rings, liner • Bearing surfaces in gearboxes rear axes etc. • Crank shaft bearings • Other surfaces of interest

5. Practical and economical aspects of the implementation of LST

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> Please explain briefly your expertise Svensk Verktygsteknik is a Swedish based research & development institute in the field of manufacturing processes. The key role is to through application research implement new technologies and productions processes mainly for automotive manufacturers and tier 1-2 suppliers around the world. Through our combination of RTD-projects and commercial engineering projects we bring the latest technology to our customers and remain updated with the needs of the manufacturing industry. This makes us a competitive partner assisting our customers in their effort to develop and maintain world class performance. To be able to support our customers in the best way possible, we cooperate with companies, institutes and universities in Europe and the US, thus accessing leading researchers and modern experimental equipment. One of our expertise areas is in the area of development of the laser material processing technology for several applications. We have a strong relationship with the Division of Manufacturing Systems at Luleå university of technology where we mostly carry through our laser experimental work by Dr. Hans Gedda. The University has several laser types suitable for LST processing. Dr. Gedda is our specialist in that area and has long experience of laser surface treatment. > Explain what kind of partner/expertise you are looking for Preferable partner to collaborate in this project is the from the automotive power train component manufacturer. But even other interested of improved tribological performance of friction units lubricated with oil

Contact information

Full name Hans Gedda



Address Aurorum 6


Country Sweden

Tel. + 46 920 759 14

Fax. +46 920 759 55

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Workshop Priority (Please select one or more from the list below) A,B Kind of partner expected

(please select one or more from the list below) I, R, C and O

Workshop Priorities:






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Project ideas

Products, equipment, systems

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> Title Adaptive Rear Combination Lamp with L.E.D. and with ambient light and soiling sensor for vehicle. > Describe your project idea The aim of this project is to design and manufacture a rear combination lamp for vehicle by using L.E.Ds as light sources instead of traditional bulbs. Adaptive function of this new generation rear combination lamp is provided by using ambient light sensor to sense the ambient light at daytime or night and adjust the luminance intensity according to ambient light automatically and by using soiling sensor to sense the degree of the dirtiness on the lens surface and adjust the luminance intensity according to this dirtiness degree. > Please explain briefly your expertise Shortly, Farplas is an international leading company in the global automotive supply industry, providing interior ceiling systems, interior / exterior lighting equipments, trimming parts and accessories for major OEM companies within Turkey and around the globe. Farplas has a lot of exterior lighting devices’ projects including both bulbs and L.E.D.s for all over the world. Farplas has designed and manufactured lighting devices including bulbs for more than 30 years, for example; stop lamps, front director indicators, sidemarkers with bulbs for Evobus, Mercedes Benz Turk, BMC, Fiat-Otoyol, Otokar, TEMSA, ISUZU etc. Farplas has started to design and manufacture Side Marker Lamps with L.E.Ds for Mercedes Benz Turk, BMC, Fiat-Otoyol, etc. since 2003. At the end of 2006, Farplas decided to design and manufacture single lamps project with L.E.Ds including stop, tail, fog, reversing and signal functions. This project has been managed by Farplas, TUBITAK and Gebze Institute of Technology (GYTE), concurrently. Now, this project is finished successfully. During this project, Farplas was responsible for plastics conceptual design and mechanical design, electronic design and optical design. Farplas has had a lot experiences about through-hole piranha type L.E.Ds for automotive exterior lighting. > Explain what kind of partner/expertise you are looking for Farplas has a lot of experiences in L.E.Ds, optical parameters, electronic design requirements and especially plastics design during this project. But this new project will include adaptive functions related to sensor technology and new version electronic design. The previous project’s light source was through-hole piranha type L.E.Ds. But in this new project, SMD type L.E.Ds will be used as light source. Because of these reasons, Farplas is looking for partners which have experiences in;

• Sensor technology especially ambient light and soiling sensors • SMD type L.E.Ds for automotive exterior rear lightings • Electronic design especially automotive new generation lighting • Optical design in automotive lighting especially fresnel lenses.

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Contact information

Full name UFUK DEMİR


Organisation name FARDİZAYN TASARIM TEKNOPARK TİC. LTD. ŞTİ.

Address GOSB Teknopark Kemal Nehrozoğlu Caddesi üretim Binası 1. Blok No:1-2

City Gebze / KOCAELİ Zip 41480

Country TÜRKİYE

Tel. 0090 262 678 89 24

Fax. 0090 262 678 89 30

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> Title APAC - Advanced Production of Automotive Components

> Describe your project idea To use the advanced technologies to manufacture car components owning improved performances on:

- Tribological characteristics. - LCA – Life Cycle Analysis. - Fatigue and wear.

The technologies to be used are: - Moulds and tools texturing, using laser or similar, for metal sheet forming. - Laser welding and surfacing. - Rapid manufacturing of metallic components. - Fibre reinforced plastic, replacing metal safety parts.

The manufactured components will be fitted on - Braking systems. - Steering systems. - Shock absorber systems. - Tools for plastic injection or metal sheet forming.

> Please explain briefly your expertise SAT TECNOLOGY is involved in EUREKA projects from more than 20 years. The main manufacturing companies from North Spain are the project partners of the more than 25 EUREKA projects successfully completed, where SAT is supplying services about project setting up and management, besides technical support on laser and optical technologies.

> Explain what kind of partner/expertise you are looking for Industries, preferably SME’s, able to participate as partner co-developing technologies or materials, or tools, or other applications. Technological suppliers (Universities…) able to bring to the project also end-users for the products/processes developed. Contact information

Full name Pedro SANZ


Organisation name SAT TECNOLOGIA

Address C/ Iturrama, 15

City Pamplona Zip 31007

Country Spain

Tel. +34 948 07 66 97

Fax. +34 948 07 67 62

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Workshop Priority (Please select one or more from the list below) A,B,C Kind of partner expected

(please select one or more from the list below) I,R,C Workshop Priorities:






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> Title Central-controlled New Style Intelligent Service Set > Describe your project idea The aim of this project is to design and manufacture a service set with dimmable L.E.D. reading light by passenger, controlling with serial communication, unique addressing for each service set, and self error analyse. In this new project; dimmable reading light brings to be adjusted the luminance intensity by passenger and this function is provided by using PWM driving technique. Controlling with serial communication brings to be managed all service sets in vehicle by using a central control unit in dashboard. Unique addressing brings to be controlled each service set and each function of that service set individually. Self error analyse brings to be detected function errors such as L.E.D. and button faults, in each service set. > Please explain briefly your expertise Shortly, Farplas is an international leading company in the global automotive supply industry, providing interior ceiling systems, interior / exterior lighting equipments, trimming parts and accessories for major OEM companies within Turkey and around the globe. Farplas has designed and manufactured service set projects including speaker, ambient light and reading light with bulb or L.E.D., air nozzles for more than 30 years for MBT(Mercedes Benz Turk), BMC, OTOYOL, OTOKAR, TEMSA, ISUZU, MAN. Farplas has a lot of experiences in service sets . For example, MBR1 Service set project for MBT includes touch button function. This method has been applied in service sets by FARPLAS. Farplas collaborated with any company from France about making an intelligent service set for aircraft. This project would have been applied for a aircraft interior part fair in Germany. This project has included following items : Individual reading light: With a short pushing on the ON/OFF button, the passenger can light or extinguish all the LED of its reading lamp. With a prolonged push, he can increase the luminosity off the LEDS.In some case, the hostess can command all the individual reading light via the Video Cabin Command Unit (VCCU). She can light or extinguish all the lights at the same time. Ambient light: The ambient light is controlled by the hostess via the VCCU. She can choose the colour (three colours available). All the ambient lights are powered on the same time. The ambient lights are constituted of led positioned behind a translucent ring that is around the individual light system. Individual ventilation: The air flow is controlled mechanically by the passenger (orientation of the ventilation, air flow rate modulation, stop of the ventilation). There are 2 ventilation systems, Loudspeaker: The loudspeaker permits to transmit the sound in the cabin. There is one loudspeaker by PSU. The volume of the sound is command by the hostess via the VCCU. Signal of call: When the passenger want to call the hostess he can push on a button present on the PSU. An aural signal is sent to the hostess, she can see on the VCCU which passenger ask her (each KSU card has a specific number). At the same time, a light is powered to permit to the hostess

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to situate the passenger in need. The light is powered off by pushing on the same button. Recall of instruction: The pilot can command the recall instructions directly. KSU electronic card: The electronic card will permit to command each KSU systems via the VCCU. Each card will be numbered in order to be recognise by the VCCU. PSU The PSU will have to integrate all the functions presented above New styling for service set In this project ; Farplas has provided design and prototype of plastic components, design and prototype of electronical systems , design a new styling for this service set and made a whole prototype of this product and exhibited in this fair. > Explain what kind of partner/expertise you are looking for Farplas has a lot of experiences in service sets. But these service sets haven’t included these intelligent applications. But this new project will include new version electronical design which provides communication between each set and central control unit, automatically. This project includes dimmable L.E.Ds reading light and ambient light. Because of these reasons, Farplas is looking for partners which have experiences in;

• Electronical design especially automotive new generation intelligent systems • Optical design in automotive lighting especially interior lighting

Contact information




Address GOSB Teknopark Kemal Nehrozoğlu Caddesi üretim Binası 1. Blok No:1-2


Country TÜRKİYE

Tel. 0090 262 678 89 24

Fax. 0090 262 678 89 30

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> Title

Electromagnetic pulse joining of cables to terminals for the automotive sector


capacitor battery to create a high pulse current under a very short time period through a coil. Large currents run through the coil and take the form of a damped sinus wave. This creates a pulsed magnetic field which induces eddy currents in any conductive materials nearby the coil. The eddy currents induced in the nearby metallic material will be in opposite direction of the primary current and this generates a magnetic force, the Lorentz force, which deforms the material. The whole process is taken less then 100µs and the performance of the process is strongly related to a correct design of the forming/joining coil.

Electromagnetic pulse crimping/welding of cable-terminals is a growing technology to manufacture high-voltage cables and terminals. From several customers around the world following advantages has been recognised with this technology:

1 Low cost process 2 High rate process < 100μs 3 Extremely stable and reliable process 4 A solid state weld is achieved between cable and connector 5 Improved connection and strength between cable and connector then for traditional

welded specimens. 6 Decreased heat in the joint at high current flows i.e. lower static heat due to

decreased resistance. 7 Almost all combinations of dissimilar material can be joined 8 All type of crimping shape is possible i.e. circular, elliptical and rectangular. 9 `Green process` : No heat, radiation, smokes or gases

Some pictures of cross-cuts of cable connections made by electromagnetic pulse processes are shown in figure 1 and pictures of cables in figure 2. If required a physical demonstrator can be send to the potential end-user.

a) b)

c) Figure 1 Cross-cut of a) al-connector to copper cable at magnitude x12, b) the same in magnitude x25 and c) a rectangular cable.

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Figure 2 show some examples of cable-connectors made by the electromagnetic pulse process. This project idea is to develop and analyse the electromagnetic pulse joining of cables to terminals with these goals:

1 Enable durable low resistance connection between cable to terminals 2 Prevent oxidation in the joint 3 Resistance values will meet USCAR-21 specs 4 Analyze the potential to manufacture up to 300 connections per minute

When the type of material and cable-terminal geometries has been decided a typical pilot

production initiative could look like this: 1. Feasibility analysis the proposed project

a. Svensk Verktygsteknik provides more detailed info based on prior experience/know how.

2. Feasibility yes, then Pilot Production Initiative will start b. Mutual NDA will be signed to enable free flow of information c. Customer provides drawings and samples d. Svensk Verktygsteknik analyse the drawings and if needed design

modifications to enable EMP process e. Customer agrees on advised modifications f. Svensk Verktygsteknik prepares pilot production set up (coil & tool design,

process set-up) g. Svensk Verktygsteknik and the customer share the responsible for coil

manufacturing in agreement of specifications h. Svensk Verktygsteknik conducts the experimental electromagnetic pulse tests

in their system i. Svensk Verktygsteknik conducts required tests (peel, metallurgic, tensile, etc)

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j. Svensk Verktygsteknik provides lab reports k. Svensk Verktygsteknik provides parts to the customer based on specifications





One of our expertise areas is to analyze and implement electromagnetic pulse processes in manufacturing systems for different type of applications. For pilot production initiative to develop and analyse the process we have the state of the art electromagnetic pulse system in our lab. In this field we also collaborate with the best supplier of electromagnetic pulse system in the world; namely Pulsar from Israel. > Explain what kind of partner/expertise you are looking for


Contact information




Address Aurorum 6


Country Sweden

Tel. +46 920-75917

Fax. +46 920-75955

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> Title European benchmark study of production efficiency at shop-floor level

> Describe your project idea The Productivity Potential Assessment (PPA) method has been developed in Sweden with the purpose to discover and analyse the potential for improving existing production at shop-floor level. To this date almost 50 studies have been completed and the conclusion in short is that there is a great potential of improving the production in Sweden. This potential is seldom considered today when decisions are taken to outsource production to low-cost countries. The project idea is to make similar studies in other (high-cost) European countries using the same method, and thus being able to benchmark performance at shop-floor level between companies in different countries. The PPA method is already translated to English (still draft version) but the method need be validated in other industrial and national circumstances. A PPA study is completed in just one day by certified experts, usually experienced industrial engineering consultants. The study is focused on utilization of manual labour in combination with machine efficiency and an overall analysis of the company’s production system. > Please explain briefly your expertise

> Explain what kind of partner/expertise you are looking for Academics, research institutes, or business organisations in different European countries. Multinational companies that are interested in objective comparison of their factories in different countries. Contact information

Full name Anders Kinnander


Organisation name Chalmers Technical University

Address Chalmersplatsen

City Gothenburg Zip 412 96

Country Sweden

Tel. +46703088828

Fax. +46317721313

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Workshop Priority (Please select one or more from the list below) d Kind of partner expected

(please select one or more from the list below) I R Workshop Priorities:






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> Title Lightweight Grippers and Fixtures

> Describe your project idea FlexProp has unique knowledge and patented technology in the area of lightweight production equipment as fixtures and grippers as well as manual equipment. By utilising composite materials FlexProp has demonstrated significant weight savings, excellent robustness and enhanced performance in such equipment. FlexProp has up until today some demonstrators in use in automotive industry and is looking for partners to industrialize, evaluate, adapt and introduce the technology in Europe.

> Please explain briefly your expertise My expertise is material science combined with 10 years experience from automotive industry, in particular lightweight production equipment as grippers, fixtures and C frames for self piercing riveting and klinching.

> Explain what kind of partner/expertise you are looking for FlexProp would like to get in contact with line builders and end users.

Contact information

Full name Karl-Otto Strömberg


Organisation name FlexProp AB

Address Kilgränd 4

City Halmstad Zip 30240

Country Sweden

Tel. +46 35 184830

Fax. +46 705984831

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> Title Manufacturing Life-cycle Management (MLM) for full Change Impact Evaluation

> Describe your project idea Configuration management through the entire life-cycle is a common problem. The impact of an isolated change to a design or manufacturing process is difficult to evaluate. This project will demonstrate the possibilities enabled by an integrated information representation for the entire life-cycle of a product or manufacturing system (requirements to disposal). Furthermore, the project will also investigate the current limitations and necessary additions to international product data standards as identified by the business needs of the project participants. A cornerstone in the project will be the business needs of the participating industry partners. Already existing technology will be used to demonstrate current possibilities and the identified limitations will be used as a base for new research and development. > Please explain briefly your expertise Information modeling of requirements, product, manufacturing system and process data. International standards for product information. Systems engineering.

> Explain what kind of partner/expertise you are looking for Organisations with assembly of several product families. Expertise in computer interpretable knowledge representation. Organisations interested in extending their information support through the life-cycle of the product and manufacturing system. Organisations experiencing difficulty in their life-cycle management. Contact information

Full name Victoria Rogstrand


Organisation name KTH

Address Brinellvägen 66

City Stockholm Zip 10044

Country Sweden

Tel. +46 (0)8 790 90 78

Fax. +46 (0)8 21 08 51

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Workshop Priority (Please select one or more from the list below) D Kind of partner expected

(please select one or more from the list below) IRC Workshop Priorities:






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> Title New generation interior lighting with LED instead of conventional incandescent bulb and Fluorescent for vehicle. > Describe your project idea The aim of this project is to design and manufacture partial or continuous interior lighting by using L.E.Ds as light sources instead of fluorescent for vehicle. As known, fluorescent lamps is widely used in interior lighting in vehicle. However there are lots of disadvantages such as;

• Health issues, If a fluorescent lamp is broken, mercury can contaminate the surrounding environment and poison its inhabitants.

• Using ballast, Fluorescent lamps require a ballast to stabilize the lamp and to provide the initial striking voltage required to start the arc discharge. This increases the cost of fluorescent.

• Lifetime, Fluorescent lights have a strictly limited life, just like incandescent bulbs. The extra cost of buying such lamps is not usually justified by their low life in practical usage, especially when compared with very low cost incandescent bulbs.

• Power factor, Fluorescent lamp ballasts have a power factor of less than unity. For large installations, this makes the provision of electrical power more expensive as special measures need to be taken to bring the power factor closer to unity.

• Power harmonics, Fluorescent lamps are a non-linear load and generate harmonics on the 50 Hz or 60 Hz sinusoidal waveform of the electrical power supply. This can generate radio frequency noise in some cases. Suppression of harmonic generation is standard practice, but imperfect. Very good suppression is possible, but adds to the cost of the fluorescent fixtures.

• Optimum operating temperature, Fluorescent lamps operate best around room temperature (say, 20 °C or 68 °F). At much lower or higher temperatures, efficiency decreases and at low temperatures (below freezing) standard lamps may not start.

• Non-compact light source, • Flicker problems, • Color rendition • Dimming, Unless specifically designed and approved to accommodate dimming,

most fluorescent light fixtures cannot be connected to a standard dimmer switch used for incandescent lamps.

• Disposal and recycling, The disposal of phosphor and particularly the mercury in the tubes is an environmental issue. Mercury poses the greatest hazard to pregnant women, infants, and children. A broken fluorescent tube is more hazardous than a broken conventional incandescent bulb due to the mercury content. Because of this, the safe cleanup of broken fluorescent bulbs differs from cleanup of conventional broken glass or incandescent bulbs.

It will be provided both getting uptrend in using L.E.D in vehicle lighting and avoiding these disadvantages of fluorescent lamps and making a flexible design as partial and continuous and reducing the prices by optimizing L.E.Ds amount.

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http://en.wikipedia.org/wiki/Power_factor

http://en.wikipedia.org/wiki/Dimmer

http://en.wikipedia.org/wiki/Mercury_%28element%29

> Please explain briefly your expertise Farplas is an international leading company in the global automotive supply industry, providing interior ceiling systems, interior / exterior lighting equipments, trimming parts and accessories for major OEM companies within Turkey and around the globe. Farplas has a lot of interior lighting devices’ projects including both bulbs and L.E.D.s for all over the world. Farplas has designed and manufactured lighting devices including bulbs and fluorescent for more than 30 years, for example; reading lamps with bulbs, interior ceiling lights with fluorescent for EVOBUS, MBT (Mercedes Benz Türk), BMC, OTOYOL, OTOKAR, TEMSA, ISUZU etc… Farplas has started to design and manufacture interior lights with L.E.Ds in ambient light BMC, OTOYOL, etc… At the end of 2006, Farplas decided to design and manufacture single lamps project with L.E.Ds including stop, tail, fog, reversing and signal functions. This project has been managed by Farplas, TUBITAK and GYTE, concurrently. Now, this project is finished succesfully. During this project, Farplas was responsible for plastics conceptual design and mechanical design, electronical design and optical design. Farplas has had a lot experiences about through hole piranha type L.E.Ds for automotive exterior lighting. Now, Farplas wants to design and manufacture interior ceiling light with L.E.D by using these experiences. > Explain what kind of partner/expertise you are looking for Farplas has a lot of experiences in L.E.Ds, optical parameters, electronical design requirements and especially plastics design during this project. But this new project will include new version electronical design. The previous exterior light project’s light source was through hole piranha type L.E.Ds. But in this new project, SMD type L.E.Ds will be used as light source. Because of these reasons, Farplas is looking for partners which have experiences in;

• SMD type L.E.Ds for automotive interior ceiling lightings • Electronical design especially automotive new generation L.E.Ds lighting • Optical design in automotive interior lighting especially

Contact information




Address GOSB Teknopark Kemal Nehrozoğlu Caddesi Üretim Binası 1. Blok No:1-2


Country TÜRKİYE

Tel. 0090 262 678 89 24

Fax. 0090 262 678 89 30

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> Title Study of recycled painted plastic and/or chrome-plated parts using supercritical C02 technologies. > Describe your project idea The aim is to eliminate impurities resulting from painting or chrome-plating using semi-gassy C02 solutions under supercritical conditions and minimising the loss of mechanical compounding properties obtained during the recycling process.

> Please explain briefly your expertise Expertise in Plastics, including: 1) Technical Services:

- Analysis and testing of plastic materials. - Transformation of plastic materials. - Technical advice and assistance. - Design and development of products. - Calibration of measuring and testing equipment. - Metrology of parts and components. - Environment and recycling.

2) Development and improvement of polymer materials: - Composites (nano-materials, natural fillers/fibres, active and intelligent materials, etc).- Biodegradable materials. - Improvement of the properties of traditional materials.



> Explain what kind of partner/expertise you are looking for - Manufacturers of parts using these technologies (working in automotive, construction, and electronic sectors). - Compounders/Reciclers with special single scruw-extruder machine or corrotating twin scruw-extruder machine.

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Contact information




Address Colón 66


Country Spain

Tel. 0034 961 961 262








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> Title

Vehicle Independent Electric Transmission Architecture

> Describe your project idea This concept rests on a unique but simple structure that comprises two special in wheel

electric motors axially linked by a differential gear assembly. Each in-wheel motor comprises a stator and a rotor having an inner shaft and outer shaft disposed coaxially by gearings such that the shafts may rotate at different speeds, the arrangement being such that in use the equal electromagnetic rotational force generated by each motor turns their respective wheel directly and yet cooperatively regardless of differing load conditions exerted on each wheel. Since the controller only uses the same control signals for the two motors, it is much easier and intrinsically safer than having to control two motors by software independently but in-coordination, in particular at high speed. The system thus inherits the many advantages of in-wheel motor drive systems while maintaining robustness and reliability of the differential gear. It also adds redundancy and modularity to the drivetrain, as each motor can be powered modularly to meet changing load demand. It also does not suffer from high un-sprung weight currently associated with in-wheel electric drives.

This project idea concerns the development of a novel patent-pending “Vehicle Independent Electric Transmission Architecture (VIETA)” system for future low-carbon and environmental friendly transport. The system involves a multiple of disciplines of electrical machines design, power electronics and control, mechanical structure and vehicle design. The VIETA system comprises three main subsystems:

1. Dual in-wheel electric motors 2. Power and control electronic drives 3. Axial differential link

Technical Impacts of the VIETA System Relative to a traditional mechanical power transmission VIETA offers many advantages:

- Better efficiency with drive-train losses and more recaptured braking energy - Better vehicle stability and safety due to improved torque control at the wheels - More vehicle design options without the need to fit the mechanical transmission

system - Lower costs and better reliability due to lower number of mechanical parts - Freedom from drive-train noise and vibration in the vehicle body - Excellent performance due to the novel electric motor's torque output characteristic - Reduced lifetime environment impact due to less end of life wastes for major parts - Cheaper and faster development cycles due to the mechanical simplicity.

Relative to other in-wheel motor concepts, such as MIEV, VIETA offers advantages such as: - Much shorter development time and hence less investment - Synergy of relatively simple and proven technologies - No critical software overhead for safety and redundancy - Intrinsic fail-safe feature with built-in redundancy


Svensk Verktygsteknik is a Swedish based research & development institute in the field of manufacturing processes. The key role is to through application research implement new technologies and productions processes mainly for automotive manufacturers and tier 1-2 suppliers around the world. Through our combination of RTD-projects and commercial engineering projects we bring the latest technology to our customers and remain updated with

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the needs of the manufacturing industry. This makes us a competitive partner assisting our customers in their effort to develop and maintain world class performance. To be able to support our customers in the best way possible, we cooperate with companies, institutes and universities in Europe and the US, thus accessing leading researchers and modern experimental equipment.

In this project proposal we collaborate with a couple Universities and R&D Institutes around Europe as well as with European industrial suppliers. > Explain what kind of partner/expertise you are looking for


Contact information




Address Aurorum 6


Country Sweden

Tel. +46 920-75917

Fax. +46 920-75955

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> Title

Electromagnetic pulse welding of dissimilar sheet materials for B-I-W structures


capacitor battery to create a high pulse current under a very short time period through a coil. Large currents run through the coil and take the form of a damped sinus wave. This creates a pulsed magnetic field which induces eddy currents in any conductive materials nearby the coil. The eddy currents induced in the nearby metallic material will be in opposite direction of the primary current and this generates a magnetic force, the Lorentz force, which is used for different type of applications. The whole process is taken less then 100µs and the performance of the process is strongly related to a correct design of the coil.

This process has been used since the 60´s to join tubular parts by a cold weld process. A schematic description a tubular magnetic pulse welding (MPW) is shown in figure 1, some electromagnetic parts in figure 2 and a typical microstructural shape of the joint in figure 3.

Figure 1 Schematic description of electromagnetic pulse welding (MPW) of tubular parts.

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Figure 2 Typical parts that is made by electromagnetic pulse welding (MPW).

Figure 3 Typical cross sections of the joint achieved by electromagnetic pulse welding (MPW).

This project idea is to further develop the MPW process to accomplish cold welds between dissimilar sheet material parts for the Body-In-White (BIW) structure. The joint configurations that will be analysed can either be in shape of seams or spots. The proposed materials in this study can be high-strength steels to Al-alloys but the material combinations will be discussed in more detail with the partners and end-users. The goals will be:

1. A seam weld between Al-steel without brittle carbides 2. A spot weld Al-steel without brittle carbides When the type of materials and welding geometries has been decided a typical pilot

production initiative could look like this: 1. Feasibility analysis the proposed project

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a. Svensk Verktygsteknik provides more detailed info based on prior

experience/know how. 2. Feasibility yes, then Pilot Production Initiative will start

b. Mutual NDA will be signed to enable free flow of information c. Customer provides drawings and samples d. Svensk Verktygsteknik analyse the drawings and if needed design

modifications to enable EMP process e. Customer agrees on advised modifications f. Svensk Verktygsteknik prepares pilot production set up (coil & tool design,

process set-up) g. Svensk Verktygsteknik and the customer share the responsible for coil

manufacturing in agreement of specifications h. Svensk Verktygsteknik conducts the experimental electromagnetic pulse tests

in their system i. Svensk Verktygsteknik conducts required tests (peel, metallurgic, tensile, etc) j. Svensk Verktygsteknik provides lab reports k. Svensk Verktygsteknik provides parts to the customer based on specifications





One of our expertise areas is to analyze and implement electromagnetic pulse processes in manufacturing systems for different type of applications. For pilot production initiative to develop and analyse the process we have the state of the art electromagnetic pulse system in our lab. In this field we also collaborate with the best supplier of electromagnetic pulse system in the world; namely Pulsar from Israel. > Explain what kind of partner/expertise you are looking for

The preferable partner we look for to collaborate in this project proposal will come from either an automotive manufacturer or a large component manufacturer (Tier 1-2) to the automotive industry.

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Contact information




Address Aurorum 6


Country Sweden

Tel. +46 920-75917

Fax. +46 920-75955

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> Title Hybrid Electric Transmission for Light Duty Vehicles

> Describe your project idea A new electric motor included transmission system to drive front wheels of light duty commercial vehicle will developed. Electric motor will be directly coupled to the differential box while the internal combustion engine coupled through gears, the gear ratios of the gearbox and the diff-case and torque-speed-efficiency map of the electric motor will be optimised to enhance overall transmission efficiency.

> Please explain briefly your expertise Ford Otosan, established at the end of 1950s, is one of the most innovative research-intensive companies and the sales leader in Turkey. It is located in Kocaeli, southeast of Istanbul and is close to major universities and technoparks (Boğaziçi University, Istanbul Technical University) and Tubitak Marmara Research Center. In 1966, launching Turkey’s first mass-produced automobile Anadol, Otosan laid the foundation of the Turkish automotive sector. In 1978 Ford and Otosan signed a licensing agreement as Ford – Otosan. The agreement gave Otosan the right to produce and sell the Cargo trucks and the Transit series, as well as to manufacture the engines for the Anadol and Transit. Engine plant at Eskişehir, Inönü, founded in 1979, began mass production in 1982, and it was again Otosan who, using modern manufacturing methods, produced Turkey’s first diesel engines. Turkey’s first small diesel engine ERK, too was an Otosan product. The current body of 9500 employee represents Turkey’s best and brightest. Within a short time, Ford Otosan has joined the ranks of Ford of Europe top production plants, with strong international reputations. Today, Ford Otosan has the technology and the know-how to design a complete vehicle for the domestic and international markets.

Ford Otosan Product Development Department Ford Otosan Product Department was formed in 1961 and, as of today can develop almost a complete vehicle in house. PD got involved in a unique vehicle development project with Ford in 1998 (Transit Connect/Tourneo Connect) and a brand new heavy-duty engine family development project (Ecotorq) for the new Cargo truck in 2003. Vehicle development group has just finalized design and development of new Transit and engine development team is working on new engine segments for Transit and Cargo vehicles. Engineers utilize the state of art engineering tools to develop parts and systems, simulate crash tests or cooling performance and have gained extensive knowledge and experience from countless hours and kilometers of engine and vehicle testing. Engineering resources include Design Studio (concept development, digital modelling, A-class surfacing, clay generation & modelling, rapid prototyping, color & harmony analysis, craftsmanship, design aid manufacturing) 6 Test Cells (with TUV & TSE accreditation capable of measuring performance, emissions, T/C Matching and Turbo Transient Response), Material Lab (to support material characterisation, failure root cause and micro structure analysis), Vehicle Performance Measuring Equipments (to measure speed, acceleration, brake performance, fuel consumption and noise & vibration), Fatigue Test Rigs (with programmable 6 hydraulic cylinders and SINCOTEC Resonance Frequency Fatigue Rig Test Rig), Durability Rig Test Laboratory (to support key life tests). As of January 2008, the number of engineers working in Product Development has reached 497. The PD has 15 PhD and 159 MSc degree level engineers who are internationally

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recognized in their area of expertise. 88 technician and supporting workers form the competitive employee body of the company.

Ford Otosan Research & Development Department R&D department of Ford Otosan, established in 2002, is known to be the leading structure of “pre-competitive level actions” in Turkey, regardless of the sector types, leads most of the vital projects with universities, research centers and other companies, and plays a key role in driving forward the whole process to reach the results compatible with the truly integrated European approach. R&D Department is the first automotive industry partner that has involved in a project funded by FP6 programme of EC (GREEN Integrated Project). Turkey’s first fuel cell package has been designed and developed with and consortium led by Ford Otosan. In the first quarter of 2006, Ford Otosan designed and produced its first hybrid vehicle, FOHEV (Ford Otosan Hybrid Electric Vehicle) again working with universities and research centers in Turkey. Otosan’s collaboration agreements with universities, such as Bogazici University, Istanbul Technical University, Middle East Technical University, Koc University and Marmara University, contribute to improvement of academic research. A state of the art plant, carefully initiated product development projects, projects being worthy of funding from Turkish government as well as European Commission, exceptional human resources – all these components enable Ford Otosan to thrive as a dynamic and innovative institution of high level design and development. Research activities at Ford Otosan are carried out in collaboration with universities and research centers aiming to enrich basic research within the country while contributing to social and economic development. During the past 2 years, close to 45 research projects with universities, 8 projects with research centers and 5 large consortium projects with pre-competition level partners were conducted in cooperation with researchers at the institutions. As a result of these collaborations, the numbers of intellectual property items have been reached to over 65 scientific papers, 38 patents, 28 utility models, 16 trademarks and 22 industrial designs > Explain what kind of partner/expertise you are looking for Electric Motor and Inverter Developer Power Electronics Manufacturer Driveline Manufacturer Contact information

Full name Varlik Kilic


Organisation name Ford Otomotiv Sanayi A.S.

Address Izmit Golcuk Yolu 14.km Ihsaniye Golcuk

City KOCAELI Zip 41670

Country TURKEY

Tel. +90 262 315 67 62

Fax. +90 262 315 60 04

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Workshop Priority (Please select one or more from the list below) Kind of partner expected

(please select one or more from the list below) Workshop Priorities:






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project idea catalogue final...companies, leasing, large fleets and traffic/transportation projects...

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