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  • 1.
    Asnafi, Nader
    et al.
    Volvo Car Corporation, Olofström, Sweden.
    Lassl, G.
    Volvo Car Corporation, Olofström, Sweden.
    Olsson, B.
    Sapa Profiles.
    Nilsson, T.
    Sapa Profiles.
    Theoretical and experimental analysis of hydropiercing2003In: SAE technical paper series, ISSN 0148-7191, article id 2884Article in journal (Refereed)
    Abstract [en]

    In this study, hydropiercing after hydroforming and prior to unloading was investigated. The primary purpose of this study was to investigate how the used hydropiercing method and the selected material and process parameters affect the hole quality. Hydropiercing inwards, hydropiercing by folding the ’scrap’ piece inwards and hydropiercing outwards were tested. The tube material was extruded AA6063-T4. The tube diameter and wall thickness were 107 mm and 2.5 mm respectively. Straight 1110-mm long tubes of this material were first hydroformed at 1300 bar and then hydropierced. Assuming that the largest (in magnitude) acceptable deflection at the hole edge is 0.2 mm, hydropiercing inwards at ≥ 1300 bar yield the best hole quality. However, the remaining scrap piece (in the tube) causes a handling problem that must be solved.

  • 2.
    Flyktman, Stefan
    et al.
    Örebro University, School of Science and Technology.
    Johansson, Jan
    Örebro University, School of Science and Technology.
    Tillverkningsmetoders påverkan på en transmissions vikt och tillverkningskostnad2010Independent thesis Basic level (university diploma), 10 credits / 15 HE creditsStudent thesis
    Abstract [en]

    Volvo Powertrain, VPT, in Köping currently manufactures transmissions for heavy-duty vehicles. For medium-duty vehicles Volvo purchase transmissions from their parts supplier ZF. Volvo wants to investigate the scenario to develop AMT - gearboxes for medium-duty vehicles. The I-shift model AT2412, which is designed for a maximum load of 2400 Nm and adapted for heavy-duty vehicles, would be able to function even in the medium-duty vehicles, but would be oversized and excessively heavy.

    In view of future development Volvo need to increase their knowledge in how the choices of manufacturing methods affect the mass and the manufacturing costs. They need to increase the understanding to make the optimal priorities with respect to mass and manufacturing costs. This study aimed to provide this understanding of how different processes affect a transmission design with respect to mass and measures from a given torque range. The aim of the study was to demonstrate the influence of the choice of production methods for individual items and how much it can affect the complete transmission's mass and manufacturing cost. The work was limited to analyzing the modified gears in the base unit.

    The first part of the work consisted of designing new gears designed for a maximum load of 1600 Nm, based on the same list of operations as the existing gears, which are found in AT2412. The second part consisted of revealing the factors for the different processes affecting the design regarding to fatigue and structural strength. For eight combinations of manufacturing processes the mass and manufacturing cost was calculated for each gear. Finally, a summary was made to show which combination of manufacturing methods that would give the optimum transmission based on minimum mass and minimum manufacturing cost.

    The results show that the choice of production methods leads to more or less reduction of mass of the gears. Generally, the calculations show that the gear that is ground, shootpeened and manganese phosphated get the lowest mass and become the most expensive to produce. On the other hand, lower manufacturing cost can be achieved by excluding certain manufacturing operations as shootpeening and manganese phosphate, but this must be compensated by increased facewidth of the gear, leading to increased mass.

    If VPT decide to develop a new variant of the I-shift in which the gears are designed for 1600Nm then the gearbox can be 6-11 kg lighter and the manufacturing costs of the gears can be reduced by about 10 percent.

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