Maskinverktyg till kronhjul och pinjong : Produktutveckling vid GKN Driveline Köping AB

Sammanfattning: This thesis has been carried out in cooperation with the firm GKN Driveline Köping AB subsection 6610 preparation and processing technology. The company manufactures the rear drive units and power transfer units for vehicles with four-wheel drive [Annex 1]. In the automotive industry there is major requirement for silent cars and there is constantly developing of new manufacturing methods for reducing noise from trafficked roads. The introduction of lapping gear kits for rear drive units and power transfer units resulted to the need of custom machine tools for GKN Driveline in the manufacturing process. The objective of this thesis was to improve the quality and reduce manufacturing time for the gear kits through the introduction of new machine tools. The requirement specification was set for a process capability with a Cpk greater than 1.33. The work begins with a theoretical framework of the manufacturing process that includes the processes affected by the machine tools. For tools to hard turning crown wheel [Annex 2] concept evaluation has been carried out and the determination of tolerances. The initiation of hard turning with crown wheel negatives instead of ball fixtures reduces production time generating profits. To find out the design of round grounding tool to the pinion [Annex 3], the number of guide pins has been investigated and also the tool impact on the tolerance of the spline. The process capability index has been examined, a sustainability-FMEA has been developed and an examination of the implications of the work has been carried out. Conclusions in the form of tools proposals are submitted and recommendations are followed up by proposals for further work. The work has been performed at the Department of Product Development, School of Engineering.