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

authored by: 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.
Organisation(s): Institute of Production Engineering and Machine Tools
Institute of Technical Combustion
Type: Conference contribution
Pages: 410-418
No. of pages: 9
Publication date: 26.04.2023
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Automotive Engineering, Aerospace Engineering, Mechanical Engineering, Fluid Flow and Transfer Processes
Sustainable Development Goals: SDG 7 - Affordable and Clean Energy, SDG 8 - Decent Work and Economic Growth, SDG 12 - Responsible Consumption and Production
Electronic version(s): https://doi.org/10.1007/978-3-031-28839-5_46 (Access: Open)