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