New Trends in the Automotive Drivetrain and Powertrain and their Impact on the Future of Powder Metallurgy Applications

Chairmen:

Dr Gerd Kotthoff
Dr Gerd Kotthoff
(GKN Sinter Metals, Germany)

Dr Salvator Nigarura
Dr Salvator Nigarura
(PMG Indiana, United States of America)

Introduction

The slow but steady move from the conventional combustion engine as a source for mobility to hybrid or full electric powered vehicles poses significant challenges to the powder metallurgy industry.

According to some estimates, the automotive market accounts for 70% of all powder metallurgy applications. Due to the strong dependence of the PM industry on the automotive market, any technological change in the automotive requires careful consideration from the PM community in order to assess potential impact.

This Special Interest Seminar focuses on PM technological advancements that could still deliver competitive products for tomorrow’s automotive drivetrain and powertrain. Presentations will highlight the new automotive trends that are most likely going to impact PM growth in the next decade and the required PM developments that need to be conducted to meet the new automotive expectations.

pdf Introduction (1.37 MB)

Prof. Dr.-Ing. Fritz Klocke

How PM Technology can support future transmission and drivetrain trends
by Prof. Dr.-Ing. Fritz Klocke and Dr.-Ing. Dipl.-Wirt.-Ing. Christoph Löpenhaus (Laboratory of Machine Tools (WZL), RWTH Aachen University, Germany)

Current trends in automotive drivetrain development simultaneously demand for two challenging objectives: the increase of power density and the reduction of noise emission. An integrative solution equalizing the trade-off between both aspects is the PM Technology. With PM processes, multiple degrees of freedom arise compared to the conventional process chain regarding geometry and material properties. In this paper, acoustic benefts of PM due to the characteristic damping behavior will be discussed as well as strategies for the optimization of noise excitation by a stiffness-based geometry design of densifed PM gears with FE approaches. Furthermore, existing defcits in tooth root strength compared to conventional manufactured gears will be tackled with FEbased approaches for the optimization of the tooth root geometry. As non-rollable geometries in the tooth root can result from the optimization, the potential of surface densifcation by shot-peening will be discussed as well. The presented methods will highlight new potentials in "Design for PM Gears".

pdf How PM Technology can Support Future Transmission and Drivetrain Trends (3.32 MB)

Dipl.-Wirt.-Ing. Christoph Löpenhaus

Dr Anders Flodin

PM Gear Manufacturing, Not Only Compaction and Sintering!
By Dr Anders Flodin (Höganäs AB, Sweden)

In a joint project with several companies in the powder metal business, a 6 speed manual transmission was redesigned for PM and furthermore prototyped and tested for durability, vibration overload etc. Some of the results will been presented in the world PM congress in Hamburg. This presentation will discuss around what is needed to make a gear besides the compaction and sintering. A gear poses more manufacturing challenges such as joining, heat treatment, tribology, hard fnishing, densifcation, the list can be made longer. During the project, all these challenges had to be faced and were overcomed. This presentation will look at solutions to these challenges.

pdf PM Gear Manufacturing, Not Only Compaction and Sintering! (2.15 MB)

Michael Hirsch

Densification Rolling - From Idea to Test Drive
by Mr Michael Hirsch (Profiroll Technologies GmbH, Germany)

Profroll is happy and proud to be member of the Powder Metal Gearbox Initiative (PMGI), consisting of 13 leading international partners and initiated by Höganäs AB. The main topic of the PMGI was to get a proof that PM technology is well suited for gear manufacturing of state of the art transmission gears. Profroll has tackled the task to manufacture the driven wheel of the 6th gear by rolling to densify both the tooth flank and the tooth root to generate the required wear resistance. As rolling specialist, Profroll decided to take a higher challenge to further shorten the process chain. The goal was to develop the “fnish” burnishing and densifcation rolling process (FBR-D) to reach the fnal gear quality after hardening without any costly hard fnishing process. This presentation will publish the results of this particular project and will show the prospects of this technology.

pdf Densification rolling: From the idea to the test drive (2.68 MB)

Chad Spore

Power Density: Guiding Force in Off-Highway/Agricultural Drivetrain Applications
by Mr Chad Spore (John Deere, United States of America)

The demands of the off-highway industrial has never been greater. The need for both power and reliability while improving effciency has created a challenge for increased power density. Without increasing the overall size of transmission, advancements are being made through changes in gear geometry and material along with the advanced processing such as vacuum heat treatment, shot peening, and super fnishing. This presentation will discuss these unique challenges and the opportunities for powder metallurgy within these demanding applications.

Peter Kjeldsteen

Disruptive Approach to Gears - A New Gear Technology without Teeth
by Mr Peter Kjeldsteen (Sintex A/S, Denmark)

Gears without teeth could be a disruptive technology in the future. The presentation will introduce the audience to the theory of magnetic gears in order to understand the technology. Furthermore there will be a historic overwiev of the development of magnetic gear technology from the frst patent drafted almost 100 years ago until today, where magnetic gears are being introduced into new applications where normal oil containing gears cannot fulfll the needs. The magnetic gears in the market today are used in high demanding applications like food industry, high vacuum systems and hot/ cold offshore applications, but could magnetic gears be a potential in automotive drive systems in the future?

pdf Disruptive Approach to Gears - A New Gear Technology without Teeth (3.43 MB)

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