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Integrated design and manufacturing of "net shape" forged products: application on forged differentials

Laurent Berviller 
Abstract : The work showed in this paper concern the integrated design of high series mechanicals products. The aim of this project is to increase products performances. To reach this goal, it is important to understand the context of this study. First of all, relations between the customer and the supplier are moving. The main consequence of this change is the transfer of the design step from the customer to the supplier. Moreover, we can observe an evolution of the forge process with the development of high dimensional quality forged components ("Net Shape") for automotive industry. Our design analyse of forged parts shows the potentialities of those new process are not completely exploited today. The principal reason is the bad integration of manufacture knowledge during the design step. This observation led us to create an integrated design approach including manufacture and product functionality control. This one is intuitive because, we think it is essential to adapt our work to the application. Thus, the method can be summarized in three main steps: the analyse of existing activities, the identification and knowledge acquisition to improve products and to finish, the structuring and the capitalization of those knowledge. We have applied the approach to differential forged gears. Thanks to this method, we have created an original gear geometry taking in consideration forge process constraints and potentialities. Moreover, we have highlighted the necessity to develop a specific mechanical dimensioning. In parallel, we have realised appraisals (showed in a confidential report) to collect the essential knowledge to optimize the conical gear design. The method we have created was tested on two industrial project of differential design. Some test results on gear meshing have allowed to quantify the improvement on the nominal geometry. Today, we are making some mechanical resistance tests to end the validation of the method.
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Submitted on : Tuesday, June 7, 2005 - 8:00:00 AM
Last modification on : Friday, October 23, 2020 - 4:52:05 PM
Long-term archiving on: : Thursday, September 30, 2010 - 6:54:02 PM


  • HAL Id : pastel-00001278, version 1



Laurent Berviller. Integrated design and manufacturing of "net shape" forged products: application on forged differentials. Engineering Sciences [physics]. Arts et Métiers ParisTech, 2005. English. ⟨NNT : 2005ENAM0005⟩. ⟨pastel-00001278⟩



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