gearbox demonstrator dynamik für ihre entwicklung development · 2017-04-19 · engine oil,...

Dynamik für Ihre Entwicklung Gearbox Demonstrator Development

Hervé MOTTE ARRK Shapers R&D / Innovation Manager

2 2017/03/14

AGENDA

Phase 1 – Motivation and general feasibility

Phase 2 – Engineering

Phase 2 – Manufacturing

ARRK Company overview

Next steps & perspectives

3 2017/03/14

AGENDA






4 2017/03/14 4

ARRK AT A GLANCE

Who are ARRK

Founded 1948

Turnover 418 M € (2015/16)

Worldwide > 3.500 employees

International technology group

20 ARRK companies in 15 countries

Listed on the Tokyo Stock Exchange (TSE)

Capabilities

Low Volume Production (LVP)

Tooling

Prototyping

Engineering

One of the world´s largest product development specialists

Your global product development specialist

5 2017/03/14

PRODUCT DEVELOPMENT COMPETENCE

Industries we serve: Automotive, Aerospace, Special and Commercial Vehicles, Transportation and Medical Industry

Engineering

CAE & Simulation

Test & Validation

Electrical & Electronics

Design

7 Centres of Competence

Low Volume

Production (LVP)

Composite Components

Low Volume Production Intent Components

Low Volume Complex Assemblies

Injection Moulded Parts

Batch Production Runs : 10 – 000’s

Tooling

Project Management

Prototype & Rapid Tooling

Innovative Production Tooling

Simulation, Moldflow Analysis, Stress Analysis

Tooling Maintenance, Modification & Refurbishment

Prototyping

Vacuum Castings

Block Modelling

Rapid CNC Machining

Rapid Prototyping SLA, SLS & 3D Printing

Prototyping Project Management

Full Integrated Service –Engineering, Prototyping, Tooling & Low Volume Production

6 2017/03/14

AGENDA






7 2017/03/14

MOTIVATION

• MARKET

– Light weight design is taken into account mainly for CO2 reduction but electric car autonomy increase is also a critical point.

– Existing demonstrators with low mechanical strenght, or structural parts for car body but not for engine or transmission.

• ARRK Knowhow & skills improvement

– Design and manufacturing (product and process) based on TP composites technologies.

Decision for gearbox housing demonstrator as a good compromise between complexity and feasibility

• Targets

– Produce a working demonstrator with an overmolded organo sheet based on an existing part with a conventional material concept (e.g. aluminum)

– Keep manufacturing costs of existing part in low volume production

8 2017/03/14

PHASE 1 – GENERAL FEASIBILITY

Comparison of conventional and composite gearbox results

• Reengineering of an existing aluminum gearbox determination of target values • Estimation of general feasibility with composite housing

Smart gearbox

Simulation model Smart gearbox

Simulation model Composite gearbox

(non-optimized)

Feasibility confirmed

9 2017/03/14

AGENDA






10 2017/03/14

1st concept

•Functional specification

•Function list

•Searching for solutions

•Creating different concepts

•Economical and technical evaluation

•Concept decision

1st draft

•Design 1st draft (design space)

•Topology optimization for load path and divisional plane

•Design revised draft

•Reduced FE-model and layer optimization


•Material decision

•Detailed draft and evaluation

•Approval detailed draft

Detailed design

•Creating detailed design

•Approval design

•Creating design documents

•Approval manufacturing documents

PHASE 2 – 1ST DRAFT

11 2017/03/14

1ST CONCEPT

Function Solution 1 Solution 2 Solution 3 Solution 4

Current gearing New gearing Modification of current gearing

+ costs

- no correction possible

+ compensation of different gearbox behavior

- costs

+ compensation of different gearbox behavior

- costs

Currents bearings New bearings New bearing material

+ costs

- inserts needed when in contact with carbon fibre

+ higher stiffness possible

- costs

+ Connecting to carbon fibre material if stainless steel

bearing rings

+ Stiffer bearings

- costs

injection molded bearing seat metal insert bearing seat connected bearing seat screwed inserts

+ mass

+ costs

- precision

- stiffness

+ precision

- costs

+ precision

+ stiffness

- mass

- costs

+ precision

- mass

carbon fibre organo sheet glass fibre organo sheet steel/aluminum bearing connector insert

- collision of gears due to thermal heating possible + better than alu+steel (regular) combination + comparable to current gearbox/gearing

glued flanges screwed flanges+sealing clip connection

+ no inserts needed for screws

+ compensation of manufacturing inaccuracy,

- not disamssemblable

+ disassemblable

- inserts (mass, corrosion), sealing

+ disassemblable

+ no inserts

- milling necessary, sealing

- Resistance against axial force

2 inserts 1 insert no inserts

+ no creeping and pretension force loss

- costs

+ costs

- creeping

+ costs

- creeping

dowel pin, centering screw/sleeve centering surfaces

+ high accuracy due to milling afterwards

- inserts necessary

- without inserts destruction of transition fit

+ no inserts needed

- effort for reaching accuracy

current sealing concept new sealing concept

+ costs- costs

- technical effort

glued flanges screwed flanges

see connection cover to hosuing see connection cover to hosuing

dowel pin, centering screw/sleeve centering surfaces

+ high accuracy due to milling afterwards

- inserts necessary

- without inserts destruction of transition fit

+ no inserts needed

- effort for reaching accuracy

material selection coating

Shapers' next meeting surface coating with fluid resitance

simple air drain petcock air drain petcock with labyrinth sealing

tube designed barrier

Oil drain plug Interior sensor

+ costs

+ no additional insert, mass reduction

- costs

- separate seraling or wireless data transmission

bore for sensors at bearing positions Interior sensor

- additional process- costs

- separate seraling or wireless data transmission

Direct Optical Laser Infrared sensor

+ costs

- limited resolution

+ more detailed results

- costs

+ more detailed results

- costs

splash lubrication (according to smart) dry sump circulating lubrication

+ costs

- additional lubrication sheets

- churning losses

+ lubrication precision

+ less oil contact of composite material

+ no churning losses

- costs (2 oil pumps) + reservoir

- high technical effort

+ lubrication precision

- costs oil pump

- high technical effort

- churning losses

separate oil fill plug air drain petcock for refilling oil

+ independent of possible air drain plug geometries

- design space

+ mass

+ 1 part 2 functions

- geometry constraints

removable sight glass defined oil volume oil dipstick oil fill plug at maximum oil level

+ oil level directly measurable

+ direct measurable

- costs

+ costs

+ no design modifications

- oil level not directly measurable

- seperate oil drain plug necessary

+ oil level directly measurable

- costs

- design space

- seperate oil drain plug necessary

+ robust method

+ using for oil drain possible

- design space

- tilt housing for oil drain or seperate oil drain plug

S Oil level

P Measuring temperature surface

Q Lubrication gears, bearings

R Oil (re)fill

M Air drain petcock oil proof

N Measuring temperature oil sump

O Measuring temperature bearings

J Centering housing to electrical machine

K Resistance fluids

L Air drain petcock

G Centering cover to housing

H Oil-proof input/output

I Mounting electrical machine

D Axle distance due to thermal expansion

E Connection housing to cover

F Screws

A Power transmission

B Bearing

C Axle distance due to mechanical load

http://www.e-racingmag.com/tag/le-mans-24-hour/

12 3 4

Category Description Value/Info

Dimensions Design space

Tolerances bearing positions Bearing positions ± 20µm

Tolerances flange mounting surfaces CAD

Mass without interior parts less than 5,826kg

Input torque 130 Nm at 4000 min-1

Crash loads 10g for x,y,z

Impact loads Mounting, stone chip

Thermal heating 100 °C

Power transmission According to smart gearbox

Torque support Mounting gearbox to environment

Deflection bearings due to loads

definedAccording to smart gearbox

Acoustics According to smart gearbox

Disassembly Housing and cover disassemblable

Oil proof Flanges sealing, input/output sealing

Oil level Measuring defined oil level

Temperature -30 to 100°C

Corrosion Contact corrosion

Fluid resistance Transmission oil

Fluid resistance

Engine oil, petrol, rim cleaner, antifreeze, brake

cleaner, aceton, brake fluid, batterie acid, cooling

fluid, wash chemicals

Costs Manufacturing According to smart gearbox costs

Oil drain plug

Air drain petcock ensure compansation overpressure, avoid oil loss

Oil refill plug Seperate or combined with air drain petcock

Measuring temperature Oilsump, bearings, gearbox surface

Maintenance

Geometry

Loads

Environmental

Functional

Functional specification Morphological analysis

• Deriving functions • Searching and evaluating of

several solutions • Creating different concepts

Concept evaluation

• Feasibility study • Concept rating • Concept decision

Further investigation only for appropriate concepts

Concept 1 Concept 3

12 2017/03/14

1ST CONCEPT

Concept 1 2 3 4Description Low cost concept Cage insert concept Seperate bearing insert concpet Highest precision concept

Details

- current gears, bearings, sealing

- thermoplastic bearing seat

- glass fiber organosheet

- glued flanges (housing/cover)

- no inserts at screws

- center surface housing to cover

- engine screwed to housing, centering by surface

- simple air drain petcock with tube to avoid oil loss

- air drain petcock also used for oil (re)fill

- defined oil volume

- smart lubrication concept

- measuring oil temperature at oil drain plug

- measuring bearing temperature at drilled holes

- direct surface temperature measuring


- connected insert for bearing seat

- glass fiber or carbon fiber organosheet

- screwed flanges (hosuing/cover)

- 2 inserts for each screw

- dowel pin for housing/cover centering



- oil fill plug at maximaum oil level






- metal insert for bearing seat

- glass fiber






- air drain petcock also used for oil (re)fill





- current sealing

- new gear design, new bearings

- connected insert for bearing seat

- glass fiber or carbon fiber organosheet




- engine screwed to housing, centering by dowel pin

- air drain petcock with labyrinth sealing and geometrical barrier to avoid oil loss

- sight glass for oil level inspection

- dry sump lubrication

- measuring oil temperature with interior sensor

- measuring bearing temperature with interior sensor

- optical surface temperature measuring

Pros

- lowest costs

- lowest mass

- no milling at flanges necessary (compensation with glue)

- high stiffness and strength at bearing seats

- high position and centering precision due to connected bearing

inserts

- glas fiber or carbon fiber organosheet possible

- inspection of gear mesh possible

- further cost reduction for series possible

- adequate stiffness

- adequate precision


- high stiffness and strength at bearing seats

- high position and centering precision due to connected bearing inserts

- compensation of bearing deflection possible by adjusted gear design

- glas fiber or carbon fiber organosheet possible


- bearing with higher stiffness possible

- further cost reduction for series possible

- direct oil measuring

- evaluation of detailed temperature distribution

Cons

- low stiffnes and strength at bearing seats

- only glass fiber organo sheet possible (thermal expansion)

- no inspection possible due to glued flanges

- no direct oil level measurable

- high costs

- high mass

- high costs

- high mass

- very high costs

- high mass

Not suitable to show capability of composite

Inappropriate costs

13 2017/03/14

1ST CONCEPT

FE-Analysis Basic Deriving Variants

Stiffness evaluation Concept desicion • Deriving Composite FE-

Model for feasibility analysis

Deriving counter measurements (ribs,UD)

• FE-Analysis

…

• Comparing with stiffness target (reference housing)

• Concept 3 with CF organo sheet feasible

• Concept 3 with GF organo sheet probably feasible

• Concept 1 not feasible

• Considering Basic simulation results

Concept decision

14 2017/03/14

1st concept


•Function list




•Concept decision

1st draft









Detailed design


•Approval design



PHASE 2 – 1ST DRAFT

15 2017/03/14

Deriving shape Optimization results Optimization process

Setup

• Minimization of strain energy

• Mass constraint

• Stiffness constraints

• Strength constraints

1ST DRAFT

Topology optimization

Topology optimization Deriving revised draft

16 2017/03/14

Results

• Higher thickness for 45°/-45° plys

Using especially 45°/-45° plys to further improve stiffness

Reduction of laminate thickness by mainly using 45° plys

Further local reinforcement measurements by using UD-Tapes

Derived results Optimization result Shell model for layer

optimization

Setup

• 0/90/45/-45/-45/45/90/0°

• Optimization for CF

• Laminate thickness 0.6 to 6 mm

• Balanced 45°/-45° plys

• Considering stiffness results

1ST DRAFT

Layer optimization

Optimizing thickness of several layers

Evaluation

17 2017/03/14

1ST DRAFT

Further stiffness optimization Deriving variants based on FE-Optimizations

• Detailed draft

• Stiffness, evaluation Deriving optimized UD,

flange, TP matrix and rib design

18 2017/03/14

1ST DRAFT

Feasibility analyses of manufacturing

Injection molding simulation Stamping simulation

19 2017/03/14

STAMPING SIMULATION

PAM-FORM – Composites Forming Simulation Software • Validation of preformed stamping process : shear angles


20 2017/03/14

STAMPING SIMULATION

PAM-FORM – Composites Forming Simulation Software • Validation of preformed stamping process : net-shape profile

Ply 0° stamping simulation Ply 0° outer profile

Ply 45° stamping simulation Ply 45° outer profile Feasibility denied Cutting required

after stamping

21 2017/03/14

STAMPING SIMULATION

PAM-FORM – Composites Forming Simulation Software • Validation of preformed stamping process : UD tapes

UD Tapes behaviour during stamping


Tooling design

Process optimization

Tool design optimization

22 2017/03/14

1st concept


•Function list




•Concept decision

1st draft









Detailed design


•Approval design



PHASE 2 – DETAILED DESIGN

23 2017/03/14

DETAILED DESIGN

• Detailed design with CF organo sheet • GF reinforced TP injection molding

material • Aluminum inserts for bearing position • Metal inserts for screws

24 2017/03/14

AGENDA






25 2017/03/14

MANUFACTURING

Organo sheet hot stamping process

26 2017/03/14

MANUFACTURING

Overmolding process

27 2017/03/14

DEMONSTRATOR

Assembly

Demonstrator visible on Auto Planet Booth N80 / Hall6

Weight saving 30% (cover only)

28 2017/03/14

AGENDA






29 2017/03/14

FURTHER STEPS

• First test of prototype cover to validate FE simulations

• Mapping of stamping results to consider in FE simulations

– Take into account fibers orientation after stamping

• Looking for new materials opportunities

– To reduce thickness

– To reduce cost material (glass instead of carbon fabrics, removing of UD tapes)

– To reduce processing costs (netshape preform to remove cutting phase)

• Design Optimization of prototype cover

• Design Optimization of 2nd part of gearbox

• Manufacturing of 2nd part of gearbox

• Testing with complete gearbox assembly

30 2017/03/14

QUESTIONS / ANSWERS

Contact : Hervé MOTTE R&D / Innovation Manager

[email protected] Tel +33 251 711 925

Mob +33 607 99 46 28

THANKS YOU FOR YOUR ATTENTION

Contact us

ARRK Europe Ltd

SPG Pre-Series Tooling & Prototyping B.V.

P+Z Engineering GmbH Shapers‘ Group ARRK LCO Protomoule

Caldwell Road, Nuneaton Warwickshire, CV11 4NG, United Kingdom www.arrkeurope.com [email protected]

Celsiusstraat 15 6003 DG, Weert Netherlands www.arrkeurope.com [email protected]

Frankfurter Ring 160 80807 Munich Germany www.arrk-engineering.com [email protected]

Z.I de la Bergerie Rue Gutenberg 49280 La Séguinière, France www.arrkeurope.com [email protected]

423 rue des champs de la Pierre 74540 ALBY sur CHERAN France www.arrkeurope.com [email protected]

Engineering Prototyping Tooling Low Volume Production

gearbox demonstrator dynamik für ihre entwicklung development · 2017-04-19 · engine oil,...

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