Simufact 12 th Round Table Conference Bamberg, Germany

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1 Simufact 12 th Round Table Conference Bamberg, Germany Design Robustness & Process Capability By Simufact & 6 Sigma Dr. Kunding Wang/Principal FEA Analyst Luk USA LLC Wooster, Ohio, USA Schaeffler Group Automotive

2 Product Range Automotive Variable valve timing Finger follower with hydr. pivot element Hydraulic tappet Clutch release system Dual mass flywheel CVT components Timing chain drive Engine and Transmission Components Balance shaft with reduced mass SAC Components for Clutch and transmission systems Overrunning alternator pulley Drawn needle bearing Shifting system Toothed chain for timing drives Ball screw drive Strut bearing Wheel- Modules Transmission brg. Deep grooved ball bearing Tapered roller brg. Tandem angular Sensor-wheel bering contact ball bearing Dual clutch system dry/wet Torque converter Page 2

3 Outline 1. Simufact as simulation tool for Manufacturing process. Performance evaluation. Durability life assessment. Robustness and capability prediction. 2. Summary. 3. Q & A. Page 3

4 Automotive Torque Converter Page 4

5 Integrated Product Development Page 5

6 Rapid Process Optimization Demand Growth Added Simufact.forming GP + Heat Treatment + Welding Started Simufact.forming + Riveting Forming + Tooling Page 6

7 Simulation Classification Total Simulations Process Simulations Performance Simulations Types Softwares Users Types Softwares Users Forming Tooling Simufact.forming Simufact.forming Tool CAE Designers Specialists Product function evaluation Product durability assessment Non-Simufact Non-Simufact CAE Specialists Riveting Simufact.forming Product robustness prediction Non-Simufact Welding Simufact.forming CAE Specialists Heat Treatment Simufact.forming Take the model, and use it for further process optimization. Take the solution (t16), and use it for performance simulations Page 7

8 Simufact Flange Forming Optimization Objective: Stamp flange from coil steel instead of machined forging. Benefits: Reduce overall cost More value added in-house Page 8

9 Simufact Stamp Stator Optimization Objective: Stamp stator instead of die cast aluminum Benefits: Cost reduction potential Performance improvement potential Page 9

10 Simufact Blind Riveting Simulation Objective: Design and process optimization Benefits: Reduce develop time Reduce prototypes Reduce developmental tests Drive inventive design and process Punch Piston Rivet Cover Riveting Die Page 10

11 Simufact Quenching Process Optimization Objective: Eliminate quenching cracks Avoid excessive quenching distortion Quenching crack Benefits: Reduced scraps Simufact optimized process reduced quenching distortion Simufact optimized process to eliminate quenching cracks Page 11

12 Simufact Durability Life Assessment Methodology Overbend Piston sfforminggp Forming Simulation σ ε Geo Overbend stress analysis σ ε Pressure cycling stress analysis σ ε Goodman Analysis Δσ Overbend Force S-N Curve Cycles Page 12

13 Overbend Piston Durability Assessment Forming Overbend Pressure cycling Overbend by forming Pressure Cycling Durability Assessment Permanent Set Page 13

14 Diaphragm Spring Performance Evaluation Quenching - Forming Simufact Tempering Shot peening Testing Page 14

15 Simufact Performance Evaluation 1 st Stroke F 2 nd Stroke Testing x Page 15

16 Simufact Drives Inventive Process Design Original Design Some damages No damage Multiple patents Page 16

17 Simufact MIG Weld Joint Durability Assessment Back plate Drive ring Hub Front cover Bolted to the dyno thru. the flex plate ω P Dynamic Page 17

18 TCC Piston plate rivet joint design Functions: Join the piston and the drive ring Transmitting torque Requirements: Durable pressure cycling Avoid automatic transmission fluid leakage Page 18

19 Simufact 6σ Rivet Joint Robustness 1. Concurrent Simulation 2. FEA DOE Optimization Apply Pressure 4. Pre-Screening Feasible Solutions 3. Robustness & Capability Page 19

20 Simufact Rivet Joint Modeling Rigid stripper Rigid punch Case Hardened Strain limit: < 2% Rivet Carbon steel Piston plate Carbon steel HR Friction paper Page 20

21 6 σ Rivet Joint DOE Table Critical Factors Control Output Page 21

22 Rivet Joint Robustness & Process Capability Page 22

23 Benefits Pre-screen Feasible Solutions Benefits Prototypes Lead Time % Budget % Design Robustness DOE % 100% Requirement FEA DOE 3 25% 20% > Requirement Avoidance 9 75% 80% Page 23

24 Summary 1. Simufact based performance simulation is successfully developed. 2. Process simulation is integrated with product development. 3. Sophisticated technology is used by tool designer. 4. Simufact simulation biomes a strategic tool in product development. 5. Simufact based process and performance simulations. q improves accuracy, efficiency, and confidence. q reduces developmental tests. q shortens development cycles. q reduces production cost. q increases knowledge retention. q drives inventive design and process. multiple patents trade secrets Page 24

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