1

FFI Sustainable gear transmission realization

To secure a future for competitive and sustainable production of high performance gears within Sweden.

2

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

3

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

4

WP2 Gear servicelife efficiencyKTH, Scania, Volvo, Saab Automobile

WP4 Robust designand manufacturingKTH, Scania, Volvo,Weigl, LEAX, Meritor

WP3 GearmaterialsChalmers, Scania, Volvo, Componenta Wirsbo, Ovako, Sandvik Coromant

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?

O

A B C

D E

F

G

Op.101

Op.102

Op.20

Op.301 Op.302

Op.40

Op.50

Datum-hierarchy diagramfor analyzing coherenceof datums

Finished part

C B Ab a

Measuring (CMM)

Bevel gear cutting End-machining and centre drilling

B’ A’

B A

b’ a’

Intermediate operations

The schematic plan provides a processover-view and possibilities for detailed descriptions

Systematic evaluation of each operation

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?

O

A B C

D E

F

G

Op.101

Op.102

Op.20

Op.301 Op.302

Op.40

Op.50

O

A B C

D E

F

G

O

A B C

D E

F

G

Op.101

Op.102

Op.20

Op.301 Op.302

Op.40

Op.50

Datum-hierarchy diagramfor analyzing coherenceof datums

Finished part

C B Ab a

Measuring (CMM)

Bevel gear cutting End-machining and centre drilling

B’ A’

B A

b’ a’

Intermediate operations

Finished partFinished part

C B AB Ab a

Measuring (CMM)Measuring (CMM)

Bevel gear cutting End-machining and centre drilling

B’ A’

B AB A

b’ a’

Intermediate operations

The schematic plan provides a processover-view and possibilities for detailed descriptions

Systematic evaluation of each operation

WP6 Process planningKTH, Scania, Volvo

WP5 Cutting toolsKTH, UU, SVA, Erasteel Kloster, Sandvik Coromant, Oerlikon Balzers, Ionbond, Primateria

Holistic approach

5

WP 6

Processplanning

The project from a gear part point of viewWP 2

WP 4

WP 3

WP 5

Steel plant

Gear hobbing

Gear honing

Turning

Forge shop

Iso t. anealing

Case hardening

Grinding

Drilling & thred.

Reliabletools

Kuggprofil

Gear geometry

Ytpara-metrar Gear

surface

Spån-bildning

Machin-ability

6

Budget[SEK]

KTH Chalmers Uppsala universitet, Ångström-laboratoriet

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