Abstract
Weight reduction is always a key focus in driveline design. Drive System Design have been researching a step change in the design of casings for transmissions and drivetrain systems. This method explores the opportunities presented by advances in materials and manufacturing processed for significant reductions in component weight. This research challenges aluminium and iron as the industry standard materials and casting as the manufacturing method for casings. Lightweight materials have been pioneered primarily in the motorsport industry but these are prohibitive on cost when considered in volume production. Either the material cost is too high or the manufacturing technique is too labour intensive. The study identifies the potential that still exists in current design and manufacturing philosophy and explores some of the key challenges presented by new technologies including fabrication, composite construction, injection moulding and forging. It also sets out to solve some of the design issues created by the need for strength, durability, lubrication, cooling and NVH. Ultimately, this investigation yields a design proposal for an aggressively light weighted transmission casing. It also presents evidence for potential component and tooling costs.
KEYWORDS – Transmission, Composite, MMC, Polymer, Structural