Fluid Couplings and Torque Converters Chapter 5 Classroom Manual.
Schaeffler Process Simulations: Torque Converters
Transcript of Schaeffler Process Simulations: Torque Converters
Schaeffler Process Simulations:
Torque ConvertersDrew Hilty
Torque Converter Clutch and Damper Design, Group Leader
Schaeffler Group / LuK USA
Overview
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Schaeffler Process Simulations: Torque Converters
1 Torque Converter Functionality
2 Torque Converter Development
3 Metal Forming
4 Joining Process
5 Welding
6 Full Manufacturing – Application Simulation
7 Summary
Torque Converter Functionality
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Schaeffler Process Simulations: Torque Converters
Turbine is connected to the
transmission input shaft
Engine
Locked – stator fixed to the
transmission housing
Freewheel – stator rotates
freely
Impeller is connected to
engine
Transmission
Torque Converter Functionality
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Schaeffler Process Simulations: Torque Converters
Engine
Impeller/Pump
Transmission
case
Stator/Reactor
Transmission input shaft
Turbine
Overview
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Schaeffler Process Simulations: Torque Converters
1 Torque Converter Functionality
2 Torque Converter Development
3 Metal Forming
4 Joining Process
5 Welding
6 Full Manufacturing – Application Simulation
7 Summary
Where are Process Simulations Needed?
Schaeffler Process Simulations: Torque Converters
Torque Converter Development
Component Stamping
Joining
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Welding
Overview
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Schaeffler Process Simulations: Torque Converters
1 Torque Converter Functionality
2 Torque Converter Development
3 Metal Forming
4 Joining Process
5 Welding
6 Full Manufacturing – Application Simulation
7 Summary
Spline Forming
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Schaeffler Process Simulations: Torque Converters
1st Form 2nd Form
3rd Form Final Form
Cover Plate Stamping
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Schaeffler Process Simulations: Torque Converters
Spring Retainer Development
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Schaeffler Process Simulations: Torque Converters
Pro
cess F
low
Forming of the sheet metal rivet and process
related residual stresses can be accounted for.
In vehicle conditions such as torsional loading
from springs or centrifugal loading due to
rotational speed can then be simulated and
added to durability calculations.
Forming Technology: Snap spring
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Schaeffler Process Simulations: Torque Converters
Thermal forming, stress relief, and application
conditions were considered when simulating
the snap spring. The spring application is to
control oil flow through the valve.
Snap spring
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Schaeffler Process Simulations: Torque Converters
Heated to setting temperature
Flat blank clamped into die
Cooled to room temperature
Cycled to closed position
Cycled to open position
Forming Technology: Snap spring
Forming Technology: Snap spring
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Schaeffler Process Simulations: Torque Converters
Stress prior to heat forming in fixture Max temperature during heat forming
Min temperature during cooling Stress post heat forming
Forming Technology: Snap spring
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Schaeffler Process Simulations: Torque Converters
Areas to optimize for durability improvements
Contact stress due to spring
activation
Forming Technology: Snap spring
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Schaeffler Process Simulations: Torque Converters
Stress, outer top
Stress, inner top
Stress, outer bottom
Stress, inner bottom
Theoretical vs. Simulation correlation shows
alignment between calculations.
Forming Technology: Snap spring
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Schaeffler Process Simulations: Torque Converters
Overview
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Schaeffler Process Simulations: Torque Converters
1 Torque Converter Functionality
2 Torque Converter Development
3 Metal Forming
4 Joining Process
5 Welding
6 Full Manufacturing – Application Simulation
7 Summary
Joining Technology
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Schaeffler Process Simulations: Torque Converters
Simulation goal was to investigate effects of
riveting and in vehicle conditions to determine
the impact on durability.
Joining Technology
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Schaeffler Process Simulations: Torque Converters
Joining Technology
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Schaeffler Process Simulations: Torque Converters
Application Condition
Process + Application Stress
Combined Rivet
Stress
00 0000000000000
100
200
300
400
500
600
1.E+03 1.E+04 1.E+05 1.E+06 1.E+07
Str
ess [M
Pa]
Cycles
Estimated SN-curve for 045YLF
Fatigue Assessment
Joining Technology: Multi-Rivet Coining
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Schaeffler Process Simulations: Torque Converters
Due to assembly symmetry, multiple
rivets were needed to be coined to
investigate down stream manufacturing
effects.
Joining Technology: Multi-Rivet Coining
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Schaeffler Process Simulations: Torque Converters
Analysis correlation to actual
sectioned assembly shows excellent
comparison of rivet dimensional
values.
Rivet Height
Rivet Diameter
Joining Technology: Multi-Rivet Coining
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Schaeffler Process Simulations: Torque Converters
Individual components can be assessed for
comparison to material limits, residual
forming stresses, and potential areas for
crack initiation.
Joining Technology: Multi-Rivet Coining
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Schaeffler Process Simulations: Torque Converters
Inner Ring is pressed into outer ring.
Residual rivet forming stresses are
accounted for to maintain the preload
included in the assembly.
Machine press to insert the
inner ring
Inner Ring
Outer Ring
Joining Technology: Multi-Rivet Coining
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Schaeffler Process Simulations: Torque Converters
Simulation shows the effects of over
travel in an extreme condition for the
assembly press
Joining Technology: Multi-Rivet Coining
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Schaeffler Process Simulations: Torque Converters
Outer Ring prior to press
bottoming out
Outer Ring after press
bottoms out
Overview
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Schaeffler Process Simulations: Torque Converters
1 Torque Converter Functionality
2 Torque Converter Development
3 Metal Forming
4 Joining Process
5 Welding
6 Full Manufacturing – Application Simulation
7 Summary
Welding Technology
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Schaeffler Process Simulations: Torque Converters
The outer rim weld on a torque converter,
commonly known as a closure weld, was
investigated to see how various weld
processes affects torque converter
deformation.
Welding Technology
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Schaeffler Process Simulations: Torque Converters
A process considering 3 weld torches was considered in this simulation. Distortions, residual
stress, and peak temperatures were evaluated.
Welding Technology
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Schaeffler Process Simulations: Torque Converters
A process considering 2 weld torches was considered in this simulation. Distortions, residual
stress, and peak temperatures were evaluated.
Welding Technology
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Schaeffler Process Simulations: Torque Converters
Variations between both methods can be seen in axial distortion
which allows the manufacturing process to be optimized to account
for welding effects.
Overview
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Schaeffler Process Simulations: Torque Converters
1 Torque Converter Functionality
2 Torque Converter Development
3 Metal Forming
4 Joining Process
5 Welding
6 Full Manufacturing – Application Simulation
7 Summary
Full Manufacturing – Application Simulation
Schaeffler Process Simulations: Torque Converters
Bending test
Section through driveplate and cover
Purpose of this simulation was to investigate residual stresses in the
radius of the extruded rivets. This location is typically the critical
stress location for this design. Linear static analysis of this assembly
does not account for residual compressive stresses in the rivet which
is key to fatigue life of this design.
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Full Manufacturing – Application Simulation
Schaeffler Process Simulations: Torque Converters
Section cut through unhit
extruded rivet
Section through upset rivet
Sectioned Assembly
Gapping
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Full Manufacturing – Application Simulation
Schaeffler Process Simulations: Torque Converters
Bending test:
Test fixture is rotated while
bending load is applied to
simulate a misaligned shaft
condition
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Full Manufacturing – Application Simulation
Schaeffler Process Simulations: Torque Converters
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Piston stamping residual stress
through multiple press stations
combined with riveting stresses can
be tracked through the complete
manufacturing process.
Full Manufacturing – Application Simulation
Schaeffler Process Simulations: Torque Converters
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Clutch carrier was evaluated
for durability of riveted joint
connection to transfer axial
loading and account for
manufacturing stresses.
Full Manufacturing – Application Simulation
Schaeffler Process Simulations: Torque Converters
Analysis model using symmetry
Tab Bending Riveting Application condition
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Full Manufacturing – Application Simulation
Schaeffler Process Simulations: Torque Converters
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Tab Bending
Riveting
Section of riveting joint
show similar rivet fill
Application condition 2Application condition 1
Overview
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Schaeffler Process Simulations: Torque Converters
1 Torque Converter Functionality
2 Torque Converter Development
3 Metal Forming
4 Joining Process
5 Welding
6 Full Manufacturing – Application Simulation
7 Summary
Summary
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Schaeffler Process Simulations: Torque Converters
Schaeffler simulation
capabilities for Quality
torque converter
design.
Development
Forming Technology
Joining Technology
Welding Technology
Full Manufacturing - Application