FFI Sustainable gear
transmission realization
To secure a future for competitive and sustainable
production of high performance gears within Sweden.
1
Project partners
•
•
•
•
•
•
•
•
•
•
•
•
KTH
Chalmers
Ångströmlaboratoriet
Scania
Volvo
Saab Automobile
Componenta Wirsbo
(FKG)
GETRAG (FKG)
Ionbond (FKG)
Leax (FKG)
Ovako (FKG)
SwePart Transmission
(FKG)
•
•
•
•
•
•
•
Albin Components
Erasteel Kloster
Höganäs
Meritor HVS
Oerlikon Balzers
Sandvik Coromant
SVA
2
Relevance
• Demands for low cost, environmental impact and energy consumption
are increasing.
• > 5000 people work with production of transmissions in Sweden.
• Production value of 12 billion SEK per year.
• High processing value.
Vision:
30% stronger and lighter automotive
gearboxes with near 100% transfer
efficiency in 2025
3
Holistic approach
WP2 Gear
service
life
efficiency
KTH,
Scania,
Volvo,
Saab
Automobile
WP3 Gear
materials
Chalmers,
Scania,
Volvo,
Componenta
Wirsbo,
Ovako,
Sandvik
Coromant
WP4 Robust
design
and
manufacturing
KTH, Scania,
Volvo,
Weigl, LEAX,
Meritor
WP5 Cutting tools
KTH, UU, SVA,
Erasteel Kloster,
Sandvik Coromant,
Oerlikon Balzers,
Ionbond, Primateria
WP6 Process
planning
KTH, Scania, Volvo
Finished part
b
C
B
A
Measuring (CMM)
B
a
O
A
Op.20
Op.101
Op.102
A
B
C
Op.301
Op.302
Intermediate operations
Bevel gear cutting
B’
A’
D
End-machining and centre drilling
b’
a’
E
Op.40
F
1. Main purpose of the
operation?
2. What is actually
done??
3. Which prerequisites
must be met?
4. Is it possible to
integrate with other
operation?
Op.50
G
The schematic plan provides a process
over-view and possibilities for detailed
descriptions
Datum-hierarchy diagram
for analyzing coherence
of datums
Systematic
evaluation of
each operation
4
The project from a gear part point of view
WP 2
Gear
Ytparametrar
surface
Gear honing
WP 4
Gear
geometry
Kuggprofil
Grinding
Case hardening
Gear hobbing
Drilling & thred.
WP 6
Process
planning
WP 5
Reliable
tools
Turning
Iso t. anealing
Forge shop
Steel plant
MachinSpånbildning
ability
WP 3
5
Budget
[SEK]
KTH
Chalmers
Uppsala
universitet,
Ångströmlaboratoriet
Industry
Total
2009
271132
900000
500000
4550000
6221132
2010
3378868
900000
900000
4550000
9728868
2011
2500000
900000
900000
3750000
8050000
Total
6150000
2700000
2300000
12850000
24000000
6