Realistic verification of manufacturing processes Step I

Important results from the project

The goal of the project is to spread and increase our knowledge of the link between production parameters and product properties using numerical simulation and experimental methodology in symbiosis. Milestones developed are questions about ´distortion´ and ´residual stresses´ for various heat treatment processes of crown wheels, and on ´simulation and prediction of cutting forces´ for machining cast iron. When new advanced materials are introduced, the crystallized research questions are strategic, as an important enabler for powertrains with smart environmental impact.

Expected long term effects

Within this project we have delivered the promised virtual tools and results in the work packages: ´Influence of process parameters on the crown wheel manufacturing´ and ´agenda for virtual simulation of machining cast iron innovation´. The results show the possibility of varying key process- and material parameters via virtual simulation providing feedback to the resultant component properties and processing parameters. This facilitates flexibility in the production process. The cases studied represent important problems in the industrial production.

Approach and implementation

The project is divided into three work packages: WPA - focused on the influence of process parameters on the driveline components, with milestones on the development of tools for the prediction of distortions. WPB is focused on modeling/simulation of machining, where we developed an innovation agenda for the machinability of cast iron materials. WPC is focused on the project lead and the coordination of activities in WPA and WPB. To obtain a successful project, we emphasize the importance of dedicated project lead, expressing clear goals and expectations to the project participants.