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Souza T.S.G.,Neumayer Tekfor Technology Center | De Souza M.M.,Neumayer Tekfor Technology Center | Savoy J.,Neumayer Tekfor Technology Center
SAE Technical Papers | Year: 2012

CO2 emission reduction through weight saving remains a huge challenge for all automotive components. When it comes to gears, the state of the art shows low potential of weight reduction due to the trade-off between mass optimization and manufacturing process. Gears are usually forged followed or not by teeth cutting operation. Current presses must operate with a minimum distance between punch and die, due to the elasticity of the equipment, in order to avoid tool failure when it operates with no working piece. Also, the press force is determined by this gap, in cases that some flash is formed during forging, and a minimum flash is required for a forgeable part using the available press. This issue constrains the minimum wall thickness of a final product, for instance, the body of an automotive gear. Therefore, some gears designs must have bigger wall thickness than the necessary due to this conceptual restriction, even if thinner walls would be approved by classical criteria, such as stiffness, permissible stress and NVH. This work analyzes an innovative solution with flexible design for gear bodies, where the assembly process eliminates the current manufacturing process trade-off. Copyright © 2012 SAE International.


De Faria J.P.,Neumayer Tekfor Technology Center | De Souza M.M.,Neumayer Tekfor Technology Center | Sigoli P.C.,Neumayer Tekfor Technology Center | Savoy J.,Neumayer Tekfor Technology Center
SAE Technical Papers | Year: 2012

Wheel hubs typically are set in vehicles through nuts with self-locking feature to assure safety. That feature may be done by an external component like a cotter pin, a deformable element incorporated to the nut like polyamide or metallic insert or some controlled mechanical deformation applied right on nut body. Nuts with some self-locking elements are being used in order to eliminate cotter pins from the system. However, during the maintenance of vehicles, some disadvantages appear like damage in thread axle due disassembling, considering controlled mechanical deformation nuts or the replacement of nut with polyamide insert to assure self-lock featuring. This paper presents a solution to replace a fastening in a current front and rear wheel-hub for a passenger vehicle. The study is made comparing a current solution, a controlled mechanical deformed nut - stover type - from a polyamide insert nut and an innovative prevailing torque nut with incorporated washer. The solution presents a fastener that does not require any element or post process to get a self-locking feature and allows its reutilization. The incorporated washer provides system maintenance cost reduction, has the advantage to be reused without axle's thread damage disassembling and is error proof during assembling against a missing washer in the system. 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.


Pereira M.H.,Neumayer Tekfor Technology Center | Sigoli P.C.,Neumayer Tekfor Technology Center | Savoy J.,Neumayer Tekfor Technology Center | De Souza M.M.,Neumayer Tekfor Technology Center
SAE Technical Papers | Year: 2013

The automotive industry seeks for lighter components in every new project. Due to strict regulations in CO2 emission and fuel consumption, design engineers are always dealing with huge challenges to manage weight reduction without structural damage for the application and manufacturing processes improvements. The drum brake system is commonly used in compact cars. This system uses two pins and two flat plates to fasten the brake shoe in the drum. A new geometry of anchor pins may contribute to achieve strict targets such as weight reduction, enhance the structural performance and also bring benefits for manufacturing processes. This work presents a new design of a lightweight drum brake anchor pin, which may contribute to the mass reduction through structural, fatigue and metal forming process simulation. © 2013 SAE INTERNATIONAL.


Novo F.M.F.,Neumayer Tekfor Technology Center | Moraes De Souza M.,Neumayer Tekfor Technology Center | Savoy J.,Neumayer Tekfor Technology Center | Silva M.A.D.C.,Neumayer Tekfor Technology Center
SAE Technical Papers | Year: 2012

Traditional propeller shafts using universal joints have been replaced by sophisticated and complex solutions that not only reduce weight, but also increase the performance of such systems in modern automotive vehicles. Due to its complexity that nowadays even may combine plastic and metallic components, traditional analytical models reach their limits to support engineers during their design phase. Particularly, in the case of their analysis under vibration, it becomes critical, as the life time of a propeller shaft and its components (bushes and joints) have to work far away from their natural frequency values. Analytical solutions seem not to be helpful anymore, when one need to reach a mostly precise value of a natural frequency of complex shafts. Although the FEM analysis nowadays is so far highly developed, they are still no responding to the increasingly demand for high accurate results in a short period of development time. This work focus on the development of a reliable method to simulate complex propeller shafts under vibration, including the components bush and joints and assessing its limits when compared to available analytical solutions. The paper presents a positive and efficient tool to the design phase of such powertrain products. Copyright © 2012 SAE International.


Valentina G.N.D.,Neumayer Tekfor Technology Center | De Souza M.M.,Neumayer Tekfor Technology Center | Savoy J.,Neumayer Tekfor Technology Center | Duque P.,Neumayer Tekfor Technology Center
SAE Technical Papers | Year: 2011

The arrival of new competitors and the continuous growth of the customer requirements, lead the OEM's to reduce the product development time; thus, the simulation tools available on the market became mandatory to the new products development in the automotive industry. However, to simulate a full connecting rod set is very time consuming. The goal of this work is to present the main simplifications that can be set on a connecting rod simulation using the Finite Elements Method (FEM) without jeopardizing the results accuracy. The main contribution of this study is to provide time optimization to the engineers and to avoid a wrong interpretation of the results according to the boundary conditions adopted on the simplified model. Copyright © 2011 SAE International.


De Abreu Duque P.,Neumayer Tekfor Technology Center | De Souza M.M.,Neumayer Tekfor Technology Center | Savoy J.,Neumayer Tekfor Technology Center | Valentina G.,Neumayer Tekfor Technology Center
SAE Technical Papers | Year: 2011

This work presents the results of a simulation using the Finite Elements Method (FEM) to study the contact pressure between cams and followers in assembled camshafts. The geometry was chosen based on an iron casting camshaft from a commercial car in order to have a base to ensure that the assembled camshaft is a great solution to increase the performance and to reduce weight. Surfaces that are in contact with high levels of contact pressure can increase the wear and reduce the lifetime of the components. In contact stress analysis, the most critical modeling consideration is to choose the ideal meshing, so, as a preparatory step we summarized with some simulations, defined an acceptable model to run 3D finite elements analysis and calculated the contact pressure. Copyright © 2011 SAE International.


Sigoli P.C.,Neumayer Tekfor Technology Center | De Souza M.M.,Neumayer Tekfor Technology Center | Savoy J.,Neumayer Tekfor Technology Center | Correa H.,Neumayer Tekfor Technology Center
SAE Technical Papers | Year: 2011

The guarantee of fastening on assembled joint is still a challenge for the designers, especially regarding the torque loss and consequent loosening of the fastening elements. Among the main reasons of accidents caused by the loosening of these elements, there is the incorrect way to apply the torque on the assembly line (too high or too low) and the possibility of jeopardizing the joint fastening due to vibration acting on the system. This paper presents a solution of fastening where the resistance of the joint loosening is given by the simultaneous application of tensile effort and prevailing torque on the elastic field of the component, which decreases the possibility of self-loosening. Copyright © 2011 SAE International.


Souza T.S.G.,Neumayer Tekfor Technology Center | De Souza M.M.,Neumayer Tekfor Technology Center | Savoy J.,Neumayer Tekfor Technology Center | Coelho C.,Neumayer Tekfor Technology Center
SAE Technical Papers | Year: 2011

The finite element method (F.E.M.), often known as finite element analysis (F.E.A.) is a design tool based on a numerical process which offers an approximate solution with enough precision for engineering independently how complex the geometry or the actuating loads are. However, the precision is function of many variables and there are some possibilities to jeopardize the result. The most important of all is the stress singularity. The target of this work is to demonstrate the stress singularity problem on a real automotive part and the way to solve it. The main contribution of this theoretical engineering analysis is to avoid a wrong interpretation of the F.E. results during the product development process. Copyright © 2011 SAE International.

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