The influence of hardening medium in the vacuum carburizing process on the distortion of machine elements used in the automotive industry

2019 ◽  
Vol 1-2 (94) ◽  
pp. 32-40 ◽  
Author(s):  
S. Pawęta ◽  
R. Pietrasik
Keyword(s):  
Automotive Industry ◽  
Gas Pressure ◽  
Furnace Chamber ◽  
Optimal Parameters ◽  
Vacuum Carburizing ◽  
Dimensional Changes ◽  
Process Gas ◽  
Hardening Process ◽  
Gas Quenching ◽  
Reducing Costs

Purpose: As part of this study, the influence of the hardening medium on distortions of FineCarb® carburized rollers used in the automotive industry as elements of fuel pumps has been examined. The analysis was carried out for the process of quenching in gas at different pressure of cooling gas and quenching in oil at variable delay time of oil mixers. Design/methodology/approach: The research was carried out on real elements used in the automotive industry as elements of fuel pumps. FineCarb® vacuum carburizing technology was used in order to obtain optimal parameters of the surface layers. During quenching a variable related to the parameters of the quenching medium was introduced. For quenching in gas it was the pressure at which nitrogen was introduced into the cooling chamber, while for quenching in oil it was the time of mixers delay. The sample batch was laid out in accordance with the PPAP (Production Part Approval Process) requirements for the automotive industry. Microhardness and radial runout measurements were carried out on the samples and subjected to statistical analysis. Findings: The analysis of each hardening processes has showed that depending on the cooling medium used, different distortion values are obtained. The distortion value is significantly influenced by the parameters of the hardening process – gas pressure/oil mixers delay. With the proposed quenching parameters, there is no relationship between the location of the sample in the furnace chamber and the distortion value. The smallest hardening distortions were obtained as a result of the hardening process in gas at a gas pressure of 3 bar. Hardening in gas was characterized by the smallest scatter values of obtained results of radial runout. Research limitations/implications: Basing on the studies and analyses carried out in this work, it can be concluded that the introduction of gas quenching technology instead of oil quenching technology is justified qualitatively and economically alike. Hardening in gas was also characterized by the smallest scatter values of obtained results of radial runout. This is an extremely important technological and economic aspect, due to the cost of grinding processing. Practical implications: The automotive and aviation industries are putting ever greater demands on the quality of manufactured components while reducing costs. Volume 94 • Issues 1-2 • May-June 2019 It requires optimization of technological processes from co-operators. In the case of hardening plants, the most important aspect is obtaining repeatable, precisely planned parameters of the carburized layer, as well as minimizing the negative phenomena that cause dimensional changes after hardening of elements. The tests allowed to determine the most effective hardening conditions in terms of obtained distortions and costs of eliminating distortions. However, the selection of the optimal parameters depends on whether the core hardness requirements are also determined. Originality/value: The conducted tests allowed to determine the most effective hardening conditions in terms of obtained distortions, costs of levelling distortions and a complete technological process for the automotive industry.

scholarly journals Evaluation and comparison of a lean production system by using SAE J4000 standard: a case study on the automotive industry in the state of Mexico

2017 ◽  
Vol 14 (4) ◽  
pp. 461
Author(s):  
Lina María Tabares
Keyword(s):  
Data Analysis ◽  
Automotive Industry ◽  
Production System ◽  
Lean Manufacturing ◽  
The State ◽  
Descriptive Statistics ◽  
Production Lines ◽  
Reducing Costs ◽  
Implementation Level

Lean manufacturing (LM) is a management system focused on eliminating waste and activities that do not add value, with the aim of reducing costs and improving the quality and productivity of organizations. LM has been adopted in diverse industries and several countries due to its advantages in cost, flexibility and rapid response (Muslimen et al., 2013). The objective of this investigation is to analyze the implementation level to the Lean System via the SAE J4000 (SAE 1999a) standard carried out among companies of the State of Mexico automotive industry. In addition, this investigation shows the inferential and descriptive statistics data analysis of Mexican companies compared to the automotive industries in Spain and Brazil. Results show that the implementation level of the automotive industry is at 48.4% in the State of Mexico according to the SAE J4000 standard. Moreover, the involvement of suppliers and the use of lean tools in processes are higher in the State of Mexico compared to automotive industries in Spain and Brazil. However, previous studies ranked the State of Mexico at a lower level of LM in contrast with Spain and Brazil production lines.

Role of European Automotive Supplier Integration in New Product Development

2011 ◽  
Vol 2 (3) ◽  
pp. 1-25
Author(s):  
Chanan S. Syan ◽  
Anthony S. White
Keyword(s):  
Product Development ◽  
New Product Development ◽  
Automotive Industry ◽  
New Product ◽  
Product Development Process ◽  
Supplier Integration ◽  
Significant Step ◽  
Reducing Costs ◽  
The Eu

Over the past two decades, the automotive industry has experienced major changes as a result of globalisation, changing customer requirements and environmental legislation. The supplier integration in the new product development process is a significant step in facilitating reduction in the time to market of innovations and reducing costs. The aim of this work is to assess the extent of supplier integration in automotive organisations and to identify what barriers still exist. An exploratory Europe-wide survey was conducted, and 31 usable returns from automotive organisations spread across the EU. The survey confirmed the increasing importance of supplier integration in the automotive industry; however, the practice varies from organisation to organisation. They also indicate that most automobile manufacturers are engaged in functional rather than strategic supplier integration, indicating that the supplier integration is not yet fully developed, but progress in the first tier of suppliers is becoming common.

Efficiency Improvement of Vacuum Carburizing by Using Natural Gas

2006 ◽  
Vol 118 ◽  
pp. 97-102
Author(s):  
Masahiro Okumiya ◽  
Satoshi Hagi ◽  
Kazuya Orita ◽  
Yoshiki Tsunekawa ◽  
Yoshito Umeda ◽  
...  
Keyword(s):  
Natural Gas ◽  
Carbon Concentration ◽  
Gas Flow ◽  
Infiltration Rate ◽  
Unsaturated Hydrocarbon ◽  
Specimen Surface ◽  
Vacuum Carburizing ◽  
Hydrocarbon Gases ◽  
Process Gas ◽  
Natural Gas Flow

Acetylene and ethylene are frequently used in vacuum carburizing in Japan. In this study the natural gas which is available from the lifeline is applied to vacuum carburizing. The gas composition inside the furnace was analyzed by the gas chromatography in order to examine the carbon infiltration mechanism. Unsaturated hydrocarbon gases (such as acetylene and ethylene) are generated from the natural gas. The effect of acetylene concentration in the furnace on the carbon infiltration rate was investigated. The carbon amount which infiltrates into the steel increases, as acetylene concentration in furnace increases. It is possible that carbon concentration of specimen surface increases to the cementite precipitation concentration in the short term, when natural gas flow rate increases in the initial carburizing stage. After that, carbon concentration of specimen surface does not decrease, even if the natural gas flow decreases, because carbon atoms which are consumed for diffusion to inside are sufficiently supplied. By using this method, inhibition of soot generation, reduction of process gas and shortening of the carburizing period are possible. The carbon concentration profile of the vacuum carburized specimen was compared with the simulation.

Heat Treating of EV Transmissions

2021 ◽  
Author(s):  
Dennis Beauchesne
Keyword(s):  
Automotive Industry ◽  
Internal Combustion Engines ◽  
Heat Treating ◽  
Combustion Engines ◽  
Vacuum Carburizing ◽  
Heat Treat ◽  
The World ◽  
Gear Manufacturing ◽  
New Challenges ◽  
Lower Tolerance

Abstract As consumers embrace Electric Vehicle (EV) technology, the automotive industry is moving quickly into replacing internal combustion engines (ICE) and traditional transmissions. The change to electrically driven vehicles offers new challenges to the gear manufacturing world, and most importantly new specifications to heat treat these gears - specifically quieter gear sets and higher torque ratings. Today’s EVs have a much lower tolerance for noise from the gear set to power the vehicle; therefore, this continues the need for even quieter and stronger gears. This technical presentation will illustrate the heat treat and distortion specifications for these new gears, along with answering the “why” of selecting low pressure vacuum carburizing (LPC) for new programs around the world.

The Development of Turboexpander-Generators for Gas Pressure Letdown Part II: Economic Analysis

2021 ◽  
Author(s):  
Jeremy Liu ◽  
Rasish Khatri ◽  
Freddie Sarhan ◽  
Eric Blumber
Keyword(s):  
Natural Gas ◽  
Economic Analysis ◽  
High Speed ◽  
Waste Heat ◽  
Axial Flow ◽  
Clean Energy ◽  
Gas Pressure ◽  
Levelized Cost Of Electricity ◽  
Process Gas ◽  
Flow Through

Abstract A family of “flow-through” turboexpander-generators (TEGs) has been developed by Calnetix Technologies for hydrogen and natural gas pressure letdown applications. A flow-through TEG includes an axial expansion turbine and can be installed directly between two flanges of an existing pipeline. TEGs can be used to generate power throughout the hydrogen and natural gas transmission infrastructure using existing pressure differentials wherever a Joule-Thomson valve is located. These can be upstream, at terminal stations, and downstream, at governor stations. The expander drives a synchronous permanent magnet high-speed generator supported by active magnetic bearings. This paper describes the innovative axial flow-through system architecture, including the use of process gas for cooling the generator rotor and stator. The primary focus of the paper is the economic analysis of the application. Various TEG subsystem design choices and their impact on cost are discussed, including the generator, bearing, expander wheel, seal, and touchdown bearing resilient mount designs. A payback analysis shows that the natural gas TEG has a payback of 2.1 years when a heat exchanger is required for preheating the gas and 1.9 years when waste heat can be used. The hydrogen TEG has a payback of 2.0 years, and does not require external preheating. Finally, a comparison of this technology with other clean energy solutions is presented, using the Levelized Cost of Electricity (LCOE) formulation. The analysis confirms that the LCOE of the expander-generator ($0.40 per megawatt-hour) compares favorably with other types of conventional and renewable energy technologies on a cost basis.

Hot Draw Mechanical Preforming of an Automotive Door Inner Panel

2008 ◽  
Author(s):  
S. George Luckey ◽  
Peter A. Friedman
Keyword(s):  
Elevated Temperature ◽  
Automotive Industry ◽  
Superplastic Forming ◽  
Gas Pressure ◽  
Die Design ◽  
Second Step ◽  
Forming Process ◽  
Forming Technology ◽  
The Press ◽  
Critical Aspects

A novel sheet metal forming technology based on aspects of both warm forming and superplastic forming has recently been developed. The new forming process, referred to as hot draw mechanical preforming (HDMP), uses two sequential steps to form a panel within a single tool at elevated temperature. In the first step, the cushion system acts on a binder and upper die to draw the blank over a punch which serves to draw in metal from the perimeter of the blank. In the second step gas pressure is applied to finish the panel details. This two step process of drawing in metal followed by gas forming can result in a significant expansion of the forming envelope for conventional AA5xxx series aluminum sheet alloys commonly used within the automotive industry. Similar to SPF, the HDMP process is performed within a single forming press equipped with heated platens and using gas pressure to shape the component during elevated temperature forming. However, the HDMP process utilizes a blankholder to control the flow of material into the forming cavity during the drawing stage and therefore requires the addition of an integrated cushion system in the bed of the press. HDMP dies are of interest in automotive applications because they maintain the low-investment attributes of SPF tooling while also significantly reducing the forming time as compared to conventional SPF. This work details the CAE based design of an HDMP die to form a one-piece aluminum door inner that can not be formed with conventionally forming processes. Critical aspects addressed in the development of the die include manufacturing targets, part design for manufacturing, and die design for operation at elevated temperature.

scholarly journals Techno-Economic Assessment of Turboexpander Application at Natural Gas Regulation Stations

Energies ◽  
2019 ◽  
Vol 12 (4) ◽  
pp. 755 ◽  
Author(s):  
Szymon Kuczyński ◽  
Mariusz Łaciak ◽  
Andrzej Olijnyk ◽  
Adam Szurlej ◽  
Tomasz Włodek
Keyword(s):  
Natural Gas ◽  
Gas Flow ◽  
Electric Energy ◽  
Economic Assessment ◽  
Gas Pressure ◽  
Operational Parameters ◽  
Pressure Regulator ◽  
Correct Operation ◽  
Process Gas ◽  
Gas Expansion

During the natural gas pipeline transportation process, gas stream pressure is reduced at natural gas regulation stations (GRS). Natural gas pressure reduction is accompanied by energy dissipation which results in irreversible exergy losses in the gas stream. Energy loss depends on the thermodynamic parameters of the natural gas stream on inlet and outlet gas pressure regulation and metering stations. Recovered energy can be used for electricity generation when the pressure regulator is replaced with an expander to drive electric energy generation. To ensure the correct operation of the system, the natural gas stream should be heated, on inlet to expander. This temperature should be higher than the gas stream during choking in the pressure regulator. The purpose of this research was to investigate GRS operational parameters which influence the efficiency of the gas expansion process and to determine selection criteria for a cost-effective application of turboexpanders at selected GRS, instead of pressure regulators. The main novelty presented in this paper shows investigation on discounted payback period (DPP) equation which depends on the annual average natural gas flow rate through the analyzed GRS, average annual level of gas expansion, average annual natural gas purchase price, average annual produced electrical energy sale price and CAPEX.

Vacuum Carburizing of AISI S7 Tool Steel

2006 ◽  
Vol 118 ◽  
pp. 91-96 ◽  
Author(s):  
Liu Ho Chiu ◽  
Yu Jen Chen ◽  
Chang Hui Wu ◽  
Heng Chang
Keyword(s):  
Fracture Toughness ◽  
High Temperature ◽  
Low Temperature ◽  
Tool Steel ◽  
Retained Austenite ◽  
Surface Hardness ◽  
Vacuum Carburizing ◽  
Modest Increase ◽  
Gas Quenching ◽  
Quenching And Tempering

The effects of vacuum carburizing under an acetylene atmosphere at 950 and 1000, followed by gas quenching and tempering at various temperatures on the properties of AISI S7 shock-resistant tool steel were studied. As carburized specimens undergo low temperature tempering, the surface hardness of the quenched specimens carburized at 1000 is lower than those of the specimens carburized at 950, due to the large amount of retained austenite in specimens carburized at 1000. Under high temperature tempering, specimens carburized at 1000 have higher surface hardness than specimens carburized at 950. As specimens are tempered in the range between 450 to 550, the surface hardness of carburized specimens show a modest increase due to the secondary hardening effects. According to the fracture toughness data, the toughness of carburized specimens peaked at tempering at 600.

Influence of the Gas Dosage Method on Pressure Changes and Technological Properties of Core Sand Used in the Technology Resol-Co2

2013 ◽  
Vol 58 (3) ◽  
pp. 891-894
Author(s):  
Ł. Jamrozowicz
Keyword(s):  
Constant Pressure ◽  
Strength Properties ◽  
Gas Pressure ◽  
Pressure Measurements ◽  
The Core ◽  
Neutral Gas ◽  
Hardening Process ◽  
Gas Consumption ◽  
Pressure Changes ◽  
Core Sand

Abstract The results of gas pressure measurements in intergranular spaces of fast-setting sands hardened by active gaseous factor are presented in the paper. The research stand and the measuring methodology are described. Investigations concern the determination and recording gas pressure changes in the core sand along the hardened core, in three measuring points. The hardening gas was introduced both in a continuous and impulse way (gas-pause) at a constant pressure. The determined pressure changes of the active gas, which takes part in the chemical reaction of the hardening process, are compared with pressure changes of the neutral gas. The influence of the impulse way of a gas dosage on the core sand strength properties is presented as well as methods of limiting the active gas consumption are shown.

scholarly journals APPLICATION OF OPTICAL PROFILOMETRY IN THE ANALYSIS OF THE DESTRUCTION PROCESS OF RENOVATION ORGANIC COATINGS FOR THE AUTOMOTIVE INDUSTRY

2019 ◽  
Vol 9 (4) ◽  
pp. 22-25
Author(s):  
Konrad Gauda ◽  
Kamil Pasierbiewicz
Keyword(s):  
Automotive Industry ◽  
Organic Coatings ◽  
Urban Atmosphere ◽  
Coating Process ◽  
Optimal Parameters ◽  
Optical Profilometry ◽  
Destruction Process ◽  
Acrylic Coatings ◽  
Climate Station

The article concerns the evaluation of the possibility of using the optical profilometry method in the analysis of the destruction process of acrylic coatings exposed at a climate station in an industrial-urban atmosphere. It was found that the observed changes do not allow to clearly assess the durability of the tested coatings. It seems that the method used may play a supporting role in assessing the quality of the coatings because the surface maps show the number and size of pores in the coating. Therefore, this method can be used, for example, to help determine the optimal parameters of the coating process (e.g. spray pressure).

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