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  • 1.
    Du-Bar, Christian
    et al.
    KTH Royal Institute of Technology, Sweden.
    Mann, Alexander
    RISE - Research Institutes of Sweden, Materials and Production, IVF.
    Wallmark, Oskar
    KTH Royal Institute of Technology, Sweden.
    Werke, Mats
    RISE - Research Institutes of Sweden, Materials and Production, IVF.
    Comparison of Performance and Manufacturing Aspects of an Insert Winding and a Hairpin Winding for an Automotive Machine Application2018In: 2018 8th International Electric Drives Production Conference, EDPC 2018 - Proceedings, Institute of Electrical and Electronics Engineers Inc. , 2018Conference paper (Refereed)
    Abstract [en]

    In this paper, two stators with different winding concepts but with the same rotor of an interior permanent magnet synchronous machine (IPMSM) type are presented. Both concepts are investigated based on their performance and their respectively stator cost and stator manufacturing aspects for a yearly production rate of 1 million units.

  • 2.
    Werke, Mats
    et al.
    RISE - Research Institutes of Sweden, Materials and Production, IVF.
    Bagge, Mats
    Scania CV AB, Sweden.
    Nicolescu, Mihai
    KTH Royal Institute of Technology, Sweden.
    Lindberg, Bengt
    KTH Royal Institute of Technology, Sweden.
    Process modelling using upstream analysis of manufacturing sequences2015In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 81, no 9-12, p. 1999-2006Article in journal (Refereed)
    Abstract [en]

    The manufacturing of components requires several manufacturing process steps that are performed in a sequence, during which the raw material is progressively converted into finished parts. The aim with simulation of manufacturing sequences is to replicate the aggregate effects of the process steps on key features of the finished product and manufacturing features. With the support of a successful simulation methodology, it will thereby be possible for process planners to evaluate virtually and select process steps to be included in the manufacturing sequence and to optimize process parameters. The motivation to implement sequential simulation in industry is therefore strong and will reduce time and cost in process planning. The modelling and simulation of complete manufacturing sequences is, however, a challenge which may lead to unrealistic and time-consuming modelling efforts and extensive computational requirements. This is due to the often complex material transformations through several consecutive process steps. In order to adapt sequential simulation into an industrial environment, simplifications are therefore necessary. This paper proposes a method for simplified metamodelling of manufacturing sequences, using upstream selection of process steps and definition of interconnected models. The method is presented as an algorithm and will improve the efficiency in the modelling of manufacturing sequences. The usability of the algorithm is demonstrated with two industrial cases: a bevel gear pinion and a steering arm.

  • 3.
    Werke, Mats
    et al.
    RISE - Research Institutes of Sweden, Materials and Production, IVF.
    Hedlind, Mikael
    Nicolescu, Mihai
    Geometric Distortion Analysis Using CAD/CAM Based Manufacturing Simulation2014In: Proceedings of the 6th International Swedish Production Symposium, Chalmers university , 2014Conference paper (Refereed)
    Abstract [en]

    Machining of components may cause geometric distortions and thereby quality issues and increased costs. This paper presents an engineering approach of CAD/CAM based manufacturing simulation in order to be in control of geometric distortions after machining. The method utilises STEP AP209 for communication of CAD/CAM simulation data. The method improves the ability to optimise process parameters, geometry, and material, in order to fulfil the design requirements. The method supports concurrent design and process planning using 3D models in CAD/CAM and FEM.

  • 4.
    Werke, Mats
    et al.
    RISE - Research Institutes of Sweden, Materials and Production, IVF.
    Kristoffersen, Hans
    RISE - Research Institutes of Sweden, Materials and Production, IVF.
    Haglund, S.
    RISE - Research Institutes of Sweden, Materials and Production, KIMAB.
    Svensson, L.
    Bharat Forge Kilsta AB.
    Nord, A.
    Bharat Forge Kilsta AB.
    Predicting residual stresses and hardness of a critical component using a combination of numerical and empirical methods2008In: Steel Research International, Wiley-VCH Verlag , 2008, Vol. 79, no 2, p. 812-819Conference paper (Refereed)
    Abstract [en]

    This paper describes the experiences gained when using numerical and empirical methods in order to predict the accumulated surface characteristics for a safety component after several forging steps, controlled cooling and blasting. The forging steps were simulated in a sequence using one Finite Element (FE) code. The output forging mesh was used as input to the cooling simulation but was too coarse in order to reflect surface characteristics. The decarburisation effect during cooling that may influence the surface characteristics was not included in the cooling model. An attempt to create a parametric model of the blasting machine with output residual stresses and hardness as a function of input residual stresses, hardness and process parameters indicated the need of further investigation concerning the physical phenomena during blasting in the machine. A new method was developed for analysing the influence of the blasted surface texture on the stress intensity. The measured residual stresses and hardness span caused by variations in the blasting process were successfully used together with the stress intensity factor as input to a fatigue strength analysis. In order to establish a seamless chain of models through the manufacturing sequence further development concerning cooling and blasting models is required. © 2008 Verlag Stahleisen GmbH, Düsseldorf.

  • 5.
    Werke, Mats
    et al.
    RISE - Research Institutes of Sweden, Materials and Production, IVF.
    Wretland, Anders
    GKN Aerospace AB, Sweden.
    Ottosson, Peter
    RISE - Research Institutes of Sweden, Materials and Production, IVF.
    Holmberg, Jonas
    RISE - Research Institutes of Sweden, Materials and Production, IVF.
    Machens, Michael
    RISE - Research Institutes of Sweden, Materials and Production, IVF.
    Semere, Daniel
    KTH Royal Institute of Technology, Sweden.
    Geometric distortion analysis using a combination of the contour method and machining simulation2018In: Procedia CIRP, 2018, p. 1481-1486Conference paper (Refereed)
    Abstract [en]

    During machining the material removal releases residual stresses introduced by previous process steps. This causes geometric machining distortions and thereby high rejection rates and costs. By simulating the process chain it is possible to predict this type of distortions. However, this requires advanced material models and accurate process- and material data for the individual processes. In order to simplify the modelling efforts a methodology that combines the contour method with machining simulation is proposed. The methodology is validated for an aerospace component using deep layer removal X-ray diffraction and CMM measurements. The methodology will improve possibilities to reduce machining distortions. © 2018 The Authors.

  • 6.
    Wärmefjord, Kristina
    et al.
    Chalmers University of Technolgy.
    Söderberg, Rickard
    Chalmers University of Technolgy.
    Ottosson, Peter
    RISE - Research Institutes of Sweden, Materials and Production, IVF.
    Werke, Mats
    RISE - Research Institutes of Sweden, Materials and Production, IVF.
    Lorin, Samuel
    Chalmers University of Technolgy.
    Lindkvist, Lars
    Chalmers University of Technolgy.
    Wandebäck, Fredrik
    RISE - Research Institutes of Sweden, Materials and Production, IVF.
    Prediction of geometrical variation of forged and stamped parts for assembly variation simulation.2013Conference paper (Other academic)
1 - 6 of 6
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