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Derse M.J.,Neumayer Tekfor Group | De Souza M.M.,Neumayer Tekfor Automotive Brazil Ltda
SAE Technical Papers | Year: 2011

In light of the global trend to reduce CO2 emissions, the pressure on the automotive industry to further reduce vehicle weights is increasing. Moreover, there is also a need to make more efficient use of the space available, in order to take account of new requirements relating to crash safety and increasing function integration (including dual-clutch transmissions and hybrid applications). When it comes to gears, the differential still offers great potential as regards the reduction of weight and size. This paper will present a new, housing-or cage-less differential that achieves the above-mentioned development goals while keeping to the familiar and tested design principle of the bevel gear set. Simultaneous product and process development and the use of high-precision forging technologies facilitate cost-effective production of this new differential. Copyright © 2011 SAE International.

Savoy J.,Neumayer Tekfor Automotive Brazil Ltda | De Souza M.M.,Neumayer Tekfor Automotive Brazil Ltda | Domingues T.G.,Neumayer Tekfor Automotive Brazil Ltda
SAE Technical Papers | Year: 2012

The constant search for more efficient combustion engines with lower levels of CO2 emissions has contributed to the development of new technologies that could reach severe global environment targets. Most of the new technologies are related to the lift and timing variation of the opening and closing of the intake valves, through variable camshafts. The controlled lift and timing variation allows the air-fuel mixture to be optimized for specific working conditions of the engine without the driver's perception. This paper presents a new design and a new operation concept for the lift variation of the intake valve. The technical and economical feasibility analysis of this new design is done through virtual studies and prototypes in the Alpha phase of the project. The valve lift control optimizes the fuel consumption, and consequently, it reduces the levels of CO2 emissions. Copyright © 2012 SAE International.

Savietto P.,Neumayer Tekfor Automotive Brazil Ltda | Savietto P.,Neumayer Tekfor Technology Center | De Souza M.M.,Neumayer Tekfor Automotive Brazil Ltda | De Souza M.M.,Neumayer Tekfor Technology Center | And 2 more authors.
SAE Technical Papers | Year: 2012

Frictional contact is a recurrent theme in engineering thanks to its ubiquity on several fields of study and the fact it can not be calculated ab initio. Furthermore, it gives rise to other complex phenomena that can only be predicted with the help of numerical methods, like the Finite Element Method (FEM). However, most FEM software still use Coulomb's local model of friction to estimate friction, which may not be reliable on predicting phenomena as complicated as the object of this paper. This work aims to simulate the stick-slip phenomenon in a press-fit and to compare this simulation with laboratory tests. The work was developed based on real cases such as the development of assembled camshafts using tubes. The structural simulations were performed using linear static analysis through the use of finite element method software. Tests were done on a digital torque tester machine used for bolts and nuts. At the end of the work the results obtained in the tests are presented. Those are compared with the virtual simulation showing a clear correlation between them. Copyright © 2012 SAE International.

Souza T.S.G.,Neumayer Tekfor Automotive Brazil Ltda | Novo F.M.F.,Neumayer Tekfor Automotive Brazil Ltda | De Souza M.M.,Neumayer Tekfor Automotive Brazil Ltda | Savoy J.,Neumayer Tekfor Automotive Brazil Ltda
SAE Technical Papers | Year: 2013

Engine downsizing is the use of a smaller engine in a vehicle that provides the power of a larger one. It is the result of car manufacturers attempting to provide more efficient vehicles by adding modern technologies, for instance, turbochargers, direct injection and variable camshaft. The smaller engine is also lighter and provides torque and power with similar performance to a much larger engine. However, the downsizing technique may lead to undesirable vibration effects on the driveline, such as structural damaging, vibration fatigue failure and extra noise. All these issues are related to natural frequencies investigation and they are often determined through the finite element method together with experimental tests during the product development phase. This work presents the finite element method limitation for natural frequencies determination of automotive components and a possible solution for the issue. © 2013 SAE INTERNATIONAL.

Savoy J.,Neumayer Tekfor Automotive Brazil Ltda | De Souza M.M.,Neumayer Tekfor Automotive Brazil Ltda | Domingues T.G.,Neumayer Tekfor Automotive Brazil Ltda | Sigoli P.C.,Neumayer Tekfor Automotive Brazil Ltda
SAE Technical Papers | Year: 2013

The search for more technical and economical competitive automotive products motivates even more the engineers to research for solutions that reduce manufacturing costs and lead-time. Bevel gears are applied extensively in the automotive industry since the invention of the transmission differential, however; few changes of the design have been done on these components in the last decades. Currently, the planetary-bevel gear blanks are hot forged with posterior cutting of the teeth and broaching of the spline, eventually, some planetary-bevel gear blanks have the teeth warm forged. The process to cold forge the teeth and the splines results as much technically benefits for the product application as manufacturing costs and lead-time reductions. This paper presents a planetary-bevel gears manufacturing concept for passenger and light commercial vehicles, where the cold forged teeth and splines present technical and economic benefits to the automotive differential transmission system. © 2013 SAE INTERNATIONAL.

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