Resource-Efficient Process Chains for the Production of High-Performance Powertrain Components in the Automotive Industry

verfasst von

Berend Denkena, Benjamin Bergmann, Marcel Wichmann, Miriam Handrup, Daniel Katzsch, Philipp Pillkahn, Leon Reuter, Christopher Schmidt, Frederik Stelljes

Abstract

This paper focuses on process chains for power train components of passenger cars and heavy duty vehicles. In the project “Powertrain 2025” particular attention is being paid to increase the resource efficiency of the manufacturing process chains and reduce energy demand during service life. In detail cylinder liners are equipped with an adapted geometry and topography which reduces friction losses. Process chains for chassis components are investigated and optimized in order to increase the resource efficiency during manufacturing, service life and maintenance. In addition, process chains for the manufacturing of drive shafts are adjusted. By eliminating hard machining, energy is saved and friction losses are reduced by laser machining of microstructures. Furthermore, micro dimples are applied in vane pumps, which leads to a tribological improvement and thus enhances their friction behaviour. Moreover, a system architecture for process planning is developed and ecologically optimized process parameters are calculated. For a final consideration, a calculation software is developed which enables to calculate the main energy consumption of the manufacturing processes and the carbon footprint for the expected service life. A weight reduction of the powertrain components of 4.5 kg per vehicle and a potential annual energy saving of 13,073 MWh is obtained.

Organisationseinheit(en)

Institut für Fertigungstechnik und Werkzeugmaschinen
Institut für Technische Verbrennung

Typ

Aufsatz in Konferenzband

Seiten

410-418

Anzahl der Seiten

9

Publikationsdatum

26.04.2023

Publikationsstatus

Veröffentlicht

Peer-reviewed

Ja

ASJC Scopus Sachgebiete

Fahrzeugbau, Luft- und Raumfahrttechnik, Maschinenbau, Fließ- und Transferprozesse von Flüssigkeiten

Ziele für nachhaltige Entwicklung

SDG 7 – Erschwingliche und saubere Energie, SDG 8 – Anständige Arbeitsbedingungen und wirtschaftliches Wachstum, SDG 12 – Verantwortungsvoller Konsum und Produktion

Elektronische Version(en)

https://doi.org/10.1007/978-3-031-28839-5_46 (Zugang: Offen)