Efficient manufacturing system for low friction surface treatment

Purpose and goal

The objective of this project has been to enable the automotive industry and its subcontractors to introduce a quality assured process for low friction treatment in production. To be able to industrialize the process in the automotive industry, the process needs to be robust and supported by quality assurance methods and quality systems that are suitable for serial production and which can be used in agreement between subcontractors and end users. Production trials have shown that the process is stable and delivered parts has performed well in verification tests.

Expected results and effects

Processing of cam follower rollers and rocker arms with Triboconditioning has shown to be able to replace today´s solutions. Friction tests of cam follower rollers show that treated rollers have lower friction than corresponding references (up to 5 times lower). Treated cam follower rollers are currently running in Scania engine test and a first stop with inspection has been made after about 500 operating hours with good results. The results delivered by the project have definitely contributed to get closer to the goals described in the FFI program "Sustainable production technology"

Planned approach and implementation

Triboconditioning of parts has been done in a CNC-late at ANS with a new hydraulic tool concept designed specially to fit the cam follower rollers. FMEA, control plan and working instructions have been used in the pilot treatment trials and a measurement system analysis has been conducted. Volvo and Gnutti Carlo has been involved in the PFMEA conducted prior to the production trials. Results from the treatment of cam follower rollers and rocker arms have been verified through friction and wear rig tests, geometrical and chemical analysis and engine tests.