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03 Schiller Resource Efficient Powertrain PDF
03 Schiller Resource Efficient Powertrain PDF
(Sven Schiller)
Summary
Part 2: Resource Efficiency in Car Manufacturing
Fraunhofer IWU
Prof. Neugebauer
2
(Frank Treppe)
low-energy engine
- conrod (weight -20 %)
- camshaft (weight -20 %)
lightweight gearing (gear rolling)
- process time:
- 30 %
- material use:
- 30 %
Conrod
Archivierungsangaben
PrecisionPrecisionforging
Camshaft
Hydroforming
Grinding
Fraunhofer IWU
Prof. Neugebauer
3
Gear shafts
Cross wedge rolling
Spin extrusion
Axial forming
Gears
Cross rolling
Propeller shafts
Spin extrusion
Flow forming
Approaches:
technical drawing
calculation / dimension of
innovative process chain
component requirements
process chain analysis
5
Archivierungsangaben
fabrication of a
prototype series
Fraunhofer IWU
Prof. Neugebauer
4
FE simulations /
virtual process
optimization,
tooling
implementation into
serial production
2. Component
development:
Solid
Conrod
weight: 408 g
Lightweight Camshaft
Analysis of current process and component requirements
new component design (reduction of final weight)
new process design
Archivierungsangaben
Fraunhofer IWU
Prof. Neugebauer
5
blank
Forge rolling or
Cross wedge
rolling
Flattening
Preforging
Finish forging
punching,
deburring,
hot calibrating
Process Chain
cutting of a billet
from the bar
inductive
heating
Preforming
Cross Wedge
Rolling
Archivierungsangaben
Forging Process
- flattening
- base forming
- final forming
(core competency IWU)
quality
control
Fraunhofer IWU
Prof. Neugebauer
6
thermal
treatment
controlled
cooling
Cutting
(punching deburring calibration)
within one complex tool system
Sizing tool
combining clipping
and piercing
Archivierungsangaben
Fraunhofer IWU
Prof. Neugebauer
7
FEM-Simulation
Archivierungsangaben
Calculation
Tool Design
2. Component
development:
Solid
Gear shaft
weight: 2950 g
Lightweight Gearshaft
Analysis of current process and component requirements
new component design (hollow shaft)
new process design using innovative technologies
Archivierungsangaben
Raw part
Minimized raw part (+ induction heating)
Swaging
Archivierungsangaben
Fraunhofer IWU
Prof. Neugebauer
10
Case Hardening
Grinding
Raw Part
Finishing
Shot Peening
Heat Treatment
Raw Part
Archivierungsangaben
Fraunhofer IWU
Prof. Neugebauer
11
Finishing
Heat Treatment
Extrusion
Spin extrusion
hydraulische
Linearachsen Linear
Hydraul.
Axis
Rotationsachsen
Archivierungsangaben
Rotation Axis
Fraunhofer IWU
Prof. Neugebauer
12
elektromechanische
Linearachsen
Elektromechani
-cal Linear Axis
Archivierungsangaben
Fraunhofer IWU
Prof. Neugebauer
14
Archivierungsangaben
Component output
Fraunhofer IWU
Prof. Neugebauer
15
Archivierungsangaben
Process parameters
Fraunhofer IWU
Prof. Neugebauer
16
Archivierungsangaben
Gearbox minimization
Fraunhofer IWU
Prof. Neugebauer
17
Archivierungsangaben
Excellent surface roughness after rolling (Ra= 0,3- 0,5m; Rz= 1,9- 3m)
Archivierungsangaben
Materials:
Fraunhofer IWU
Prof. Neugebauer
19
24
[mm]
16 24
[]
5 11
[mm]
12 34
[]
up to 2.7
8 11 (pregearing)
6/7
(finished)
case hardening steel,
heat treated steels
Archivierungsangaben
Fraunhofer IWU
Prof. Neugebauer
20
Archivierungsangaben
Rotor profiles
Fraunhofer IWU
Prof. Neugebauer
21
Archivierungsangaben
Contact:
Frank Treppe:
Sven Schiller:
Fraunhofer IWU
Prof. Neugebauer
23
frank.treppe@iwu.fraunhofer.de
sven.schiller@iwu.fraunhofer.de
Archivierungsangaben
tool
segment
outer ring
Fraunhofer IWU
Prof. Neugebauer
24
www.hmp.de
pressure
surges
compensation
plate
roll
cage