Optimised materials for robust machining - phase 2

Purpose and goal

This project addresses the challenges of sustainable manufacturing of high-added value powertrain components where product realisation through efficient and robust machining of advanced and novel materials is the key component.

Results and expected effects

The overall result will be methods and procedures for manufacture of advanced powertrain components driven by needs for improved vehicle efficiency in terms of engine performance and emission and light-weight design capabilities. Target group is powertrain manufacturing, which is a core business in Sweden. The project is expected to essentially contribute in achieving following goal within process planning and production: 30% productivity increase in the production processes. The goal of higher productivity will be achieved by better control of material specifications, material behaviour knowledge, optimised Machinability of CGI, combined materials and high strength alloys as well as access to optimised tooling concept and strategies for CGI machining. It will also be of prime importance to have access to a short-time Machinability test that can used for production control and production development, in particular when in concerns cast materials such as CGI and other cast irons. as main engine materials for heavy vehicles. There will be a critical mass of scientists addressing the industrial problems related to machining and product realisation with the highest possible competence.

Approach and implementation

The project is organised as an umbrella with two parallel lines of approach: 1) A generic part that addresses the basic aspects of material-tool interaction aimed at developing a fundamental basis for understanding how material structure influences machinability. This activity spans over a specific set of difficult-to-cut materials including also some efforts regarding combined materials. 2) More application-oriented activities addressing the product realisation through casting and machining of powertrain materials of tomorrow required for meeting the demands on engine performance set out by environmental concerns and legislation, here exemplified by the planned activities on CGI (compact graphite iron) as candidate for future heavy vehicle weight-efficient engine components. In order to address the challenges outlined above, the project is organised through following work-packages (WPs): WP1: Tool / Work Material Interaction in High Performance Machining WP2: Optimisation of CGI Component Manufacturing Specific means and actions are also included for technology and knowledge dissemination.