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A novel technique for driveline assembly applications

Coban H., Harrison D. K., De Silva A. K. M.

Journal of KONES

2011

Vol. 18, No. 4

55-63

A novel technique for drivetrain assembly - Mill-Knurling and Press-Fitting (MKPF) is projected as a substitute to laser welding or bolting. This joining practice involves the press fitting of two mating surfaces, one with mill-knurled teeth and the other which is of a comparatively softer material, enabling it to stream over the teeth making a joint. This process has been applied within an automobile rear axle differential which is subjected to random torque loads. Experimental analysis and simulation has been used to evaluate the serviceable viability and the latent benefits of mill knurled joints with both laser welded and bolted joints currently used by BMW. Assumptions such as total cost of planning, research and development, total investment, total specific resources, raw material and manufacturing costs were used to evaluate mill knurling as an alternative to laser welding and bolted assemblies. The MKPF method has been successfully applied to assemble rear axle differential cases to the bevel gears. The costs, weight and size estimations are very positive in comparison to the competitive methods of laser welding and bolting. The noteworthy weight saving will strengthen the efforts by the automotive industry to reduce the emission levels of vehicles. The pitch flank deviation values which are critical for the life cycle duty of the bevel gear need to be further investigated in order to achieve comparable results with laser welding.

Research and developments in laser beam machining

Pająk P. T., De Silva A. K. M., Harrison D. K., McGeough J. A.

Zeszyty Naukowe Politechniki Poznańskiej. Budowa Maszyn i Zarządzanie Produkcją

2005

Nr 2

63-91

This paper reviews basic relationships and parameters as well as recent trends in research and development of Laser Beam Machining (LBM), particularly emphasising on applications of novel, short and ultra-short pulsed lasers. Since laser development a lot effort has been done to improve laser performance and to limit its drawbacks. One of the main development directions are the improvement of LBM surface integrity by limitation of heat affected zone and the increase of machining accuracy particularly in micromachining. Therefore the machining needs are the main drivers for development of short and ultrashort pulsed lasers that, iasers of better beam quality, lasers of shorter wavelengths. Shorter pulses of the order of 10-15 s enable to minimise heat conduction and maximise ablation, whereas shorter wavelengths (< 300nm) are absorbed too a greater extent by the material rather than longer wavelengths. Moreover shorter wavelengths enable to produce smaller features. This paper gives also a number of various laser machining applications as well as considers modern laser beam guidance techniques.