2009 - Luleå University of Technology/sirius 09.pdf · seen as a stage in the design process...
Transcript of 2009 - Luleå University of Technology/sirius 09.pdf · seen as a stage in the design process...
2009
visiting‑address: university campus, porsön, luleå
postal address: SE-971 87 luleå, sweden
telephone: +46(0)920-49 10 00. fax: +46(0)920-996 92
website: www.ltu.se www.ltu.se/tfm/cad
FINAL-YEAR COURSE IN
MECHANICAL ENGINEERING DESIGN
IN THE MECHANICAL ENGINEERING
MSc PROGRAMME AT
LULEÅ UNIVERSIT Y OF TECHNOLOGY
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3
Sirius 2008/09 is a collaborative programme involving Luleå University of Technology
together with the Faste Laboratory partners Volvo Aero, Hägglunds Drives AB,
AB Sandvik Coromant, Gestamp Hardtech, Volvo Construction Equipment and
several other industrial and academic partners.
Sirius prepares students for work in product development. The product development
projects of this course are firmly based on close collaboration with industrial manu-
facturers or on real product development needs identified in other ways. Work is
conducted in project groups with the support and guidance of academic and
industry advisors. Collaboration benefits both students and industry partners by
giving students an opportunity to apply their knowledge when developing optimal
solutions to real design problems with a limited time frame and budget. A unique
insight into present and future working methods and cooperation in product devel-
opment is gained.
Manufacturing companies gain access to innovative product development
performed by well-educated engineers who are unbiased by traditional modes of
thinking and problem solving.
Luleå University of Technology and industry partners in collaboration
Sirius is a final-year course for students in
the Mechanical Engineering MSc degree
programme at Luleå University of Techno-
logy. Sirius is also open to final-year
students from other MSc engineering pro-
grammes at the university, thereby ensuring
a broad base of knowledge for the course’s
project groups. During most of the 22.5-
credit course, product development pro-
jects are conducted in close national and
international collaboration with compa-
nies and universities. The aim of Sirius
is for students to acquire, apply and
integrate knowledge considered essen-
tial for product developers in modern
manufacturing industries.
Students gain knowledge in project
management, production of creative con-
cepts, mechanical engineering design and
computer-aided engineering, as well as
command of all stages in the integrated
product development chain, from needs
analysis to the finished product. Under rea-
listic industrial conditions, they carry out
product development in teams, in colla-
boration with manufacturing companies
based on real needs. Experience from
Sirius prepares the participants well for
teamwork with colleagues from other
disciplines. Students also take courses
in product development methods, com-
puter-aided modelling and analysis, and
project management, courses which
support their development projects.
Sirius students engage in a valuable ex-
change of knowledge and ideas with
graduate students and staff from
the Faste Laboratory and other depart-
ments of Luleå University of Technology.
Not only do Sirius students have solid
theoretical knowledge, they also have the
benefit of valuable experience from work
in an integrated environment where me-
thods and ideas from the research at the
division of Computer Aided Design have
been applied.
Creative product development
For more information
about previous Sirius
projects, please visit
www.ltu.se/tfm/cad/
sirius.
2
NeedfindingA user focus has come to dominate compa-
ny innovation strategies in the past decade.
However, in practice, involving users in pro-
duct development is not as straightforward
as it sounds. People cannot always be pre-
cise about what their needs are; they might
just perceive a situation where satisfactory
solutions are lacking. In such situations, it
is naturally more difficult to identify these
needs. Needs obviously play an important
role in innovative or radical product design,
since the starting position includes no exis-
ting solution.
Thirty years ago, Robert McKim, the
head of Stanford University’s product design
programme, understood that engineers had
to be involved during the earliest stages
of product development to understand
needs. He developed an approach, named
Needfinding. Needfinding implies the inter-
play between needs and recognition.
Observations, interviews and creative
methods are used to identify, analyse, cate-
gorise and communicate needs to drive pro-
duct development in Sirius student projects.
The main principles of Needfinding are to first
be close to the users and then look for needs,
not solutions. This keeps the early phases
of product development open to unexpec-
ted insights and supports the generation of
numerous concept ideas. In turn, this broa-
dens the design space and the opportunities
for innovative products. This contradicts a
problem-solving approach of product deve-
lopment, where reducing the number of
concepts as early as possible is important.
Needfinding is part of the Sirius guideline that
provides students with capabilities beyond
classical engineering design education. The
insights into needs provide a solid ground
for the activities in concept generation, con-
cept evaluation, detail design and product
launch, which are also main parts in the Sirius
guideline.
Concept generationAs Needfinding activities unfold, students
gradually perceive insights into people’s
needs and concept ideas. To work the ideas
into comprehensible concepts, the use of
creative methods is emphasised. The use
of creative methods spurs a free mind and
openness to new ideas, since judgmental
attitudes are not allowed and all ideas are
good ideas. The concept generation phase
has a focus on quantity, i.e. as many ideas
as possible. Examples of creative methods
are brainstorming, method 653, brainwriting,
bodystorming, and de Bono’s six thinking
hats. The use of creative tools, e.g. method
cards and thinkpak, support thinking outside
the box and using all senses to be creative in
the concept generation activities.
Concept generation is, in particular,
highly iterative. The generation activities
occur on different levels throughout the entire
product development process as the product
matures.
of Quality and Pugh’s matrix, are used. Small
models or prototypes may be used to test if
a concept should be further developed. The
idea here is to keep the prototype as simple
as possible, since only particular concepts
should be tested. Concept generation and
concept evaluation are closely related pha-
ses and are used to narrow down and open
up the design space. The results from the
Needfinding activities, i.e. the needs in focus,
are used in the evaluation activities to, for
instance, judge a user-perceived value of the
concept.
Detail designAfter iteratively framing and reframing the
concepts in the evaluation phase, a few con-
cepts are chosen for further development.
Detail design is a stage where the concepts
become more explicit in terms of solutions
and functionality. Still, the chosen concepts
are at various stages of completion. There-
fore, a range of approaches is used. Com-
puter-aided engineering and design tools
such as multi-body dynamic analysis and
finite element analysis are used, along with
engineering design method and methodolo-
gies, e.g. case-based reasoning, knowled-
ge-based engineering, and industrial design
approaches. The Sirius course encompas-
ses a diversity of products to be developed;
thus, the choice of approach or approaches
depends on the focus in the student project.
Concept evaluationNumerous concepts are created during the
concept generation phase; approximately
100-150 concepts are not unusual. This pleth-
ora of concepts has to be narrowed down into
a manageable size during a phase referred to
as concept evaluation. Concept evaluation
can be seen as activities that highlight some
desired qualities in each concept and can be
seen as a stage in the design process during
which the design space is narrowed down.
The aim is to extract a few concepts that best
meet the needs in focus and are feasible to be
further developed into a product. However,
to build upon seemingly crazy ideas from the
concept generation, the concepts have to be
described more concretely.
A first round of evaluations can be per-
formed, for example, by using creative tools
where the focus is on judging the value of the
idea. During the later stages, measurable cri-
teria and matrix-based methods, e.g. House
Product launchCompleting the whole product development
process from identifying and understanding
needs to product launch is a basic require-
ment of the Sirius guideline. The Sirius stu-
dent projects are performed under realistic
conditions, in most cases, in collaboration
with companies. Therefore, the expectations
on the products are high. Several produc-
ts developed within the Sirius programme
are further developed and implemented
by the companies. Not only is it important
to design a competitive product in terms of
design, ergonomics, aesthetics, etc., but it
is also important that the students have the
opportunity to practice their skills in selling
and explaining their ideas. Hence, ideas
and concepts are continuously presented
to industry partners, teaching staff or both
throughout the programme. The programme
concludes with a public event during which
student projects and products are presen-
ted. This is a day when many students are
pleased to show what they have achieved,
and when the Sirius personnel are full of pride
for their students.
54
6 7
Design Space Exploration
Roadmap
Concept Design & Prototyping
Gestamp HardTechStudents were given the task to develop a
crash test cart for bumper testing. The test
cart had to be able to mimic the dynamic
behaviour of both small and large passenger
cars. Along with the final design a program
was delivered instructing the test engineer
how to set up the cart.
Hägglunds DrivesStudents have together with Hägglunds
Drives AB developed an innovative compact
hydraulic drive system suitable to power
conveyors or similar products. The system
is compact and effective and designed to be
an especially competitive drive solution for
operating at high torque and low power range.
A full-scale functional prototype was built
and evaluated. This prototype will be further
tested in the laboratory at Hägglunds Drives
AB in Mellansel during 2009 and 2010.
LTU Eco Marathon The Shell Eco Marathon is an educational
project that integrates the sustainable deve-
lopment values with driving a vehicle using
the least amount of energy.
Over the years, the fuel economy record
has been rapidly improved. Last year LTU
competed for the first time and won its class.
The vehicle, named Baldos, ran 299 km
using only one litre of gasoline, breaking the
world record in carbon dioxide emissions by
6 g/km.
In early May this year, LTU will compete in the
25th annual edition of the European Shell Eco
Marathon with a new version of Baldos. We
hope to perform even better than last year.
Sandvik CoromantTogether with AB Sandvik Coromant the stu-
dents have developed an integrated adjusting
device for indexable drilling tools, to enable
an adjustment of the peripheral insert. This
will make it possible to achieve a closer hole
tolerance.
Volvo Aero The Turbine Rear Frame (TRF) is a load carry-
ing structure located in the aft of a jet engine.
The task was to develop a new TRF design
with improved aerodynamic abilities while
considering the high operational tempera-
ture and maintaining a low weight. Together
with Volvo Aero Corporation the students
developed and evaluated a new design that
shows good robustness and good potential
for further development..
Volvo Construction EquipmentA fully functional prototype and a production-
ready model of the drop box were develo-
ped.
Success in the Shell Eco Marathon
The students from the Sirius programme in 2008 participated for
the first time in the Shell Eco Marathon. The aim of the compe-
tition is to encourage and promote innovation and ideas in the
area of climate-friendly vehicles and sustainable transportation.
The future demand for energy-efficient vehicles was a moti-
vational factor for the team. The students clearly understood,
adopted and improved the technique needed for ultra-high fuel
efficient vehicles. The hybrid powered urban vehicle named
BALDOS succeeded in the competition and was awarded seve-
ral prizes.
Baldos showed an extremely low fuel consumption of 299
Km/l, which resulted in a first place in the Michelin Grand Prize
Combustion Engine class.
A technical solution whereby the engine exhaust gas was
recirculated into the combustion engine for improved efficiency
was awarded with the Bosch Technical Innovation prize.
The technical solutions and the overall performance of the
car resulted in a minimal environmental impact during usage.
The resulting total life-cycle carbon dioxide emissions were 6.15
g CO2/Km, which includes all emissions from production, trans-
portation and final use. For this achievement, the team were
honoured with the Climate Friendly Prize.
Compact Electro-Hydraulic Variable-Speed Drive System
Hägglunds Drives has participated in SIRIUS every year since
2003/2004.
To be more competitive on the market we have to reduce
weight, number of components and at the same time improve
efficiency and reliability for our hydraulic drive systems. A good
example is a project that started up as a conceptual study in
the Sirius project 2007/2008. The students delivered a mock-
up in scale 1:2 that was presented for Hägglunds Drives in May
2008.
A decision was taken to pursue the concept and develop
a full-scale prototype for testing in our laboratory. The Sirius
project 2008/2009 has already proven that it is realistic to build
a more competitive drive system from components that can be
found on the market today.
It was also important to reduce oil volume and use a more
sophisticated oil that can withstand higher oil temperatures to
improve the cooling capacity. Close collaboration between the
divisions of Computer Aided Design and Machine Elements has
been an important factor for knowledge sharing and testing of
principles by using tribo-testing in the Tribolab at LTU.
Further testing in our laboratory in Mellansel is planned
as part of an MSc thesis project that will begin in September
2009.
Integrated Outlet Guide Vane in Aluminum
Volvo Aero Corporation (VAC) became a partner in the Sirius
Creative Product Development programme in 2001/2002 and
has participated every year since then.
In 2007/2008 the VAC project consisted of designing an
integrated outlet guide vane (OGV) in aluminum for the next-
generation single-aisle aircraft. The OGV is part of the inter-
mediate case (IMC) located right behind the fan in turbo fan
jet engines. It is traditionally made of titanium castings, which
makes it strong but very expensive. The IMC has two functions;
load transfer from the core structure of the engine, which is
conventionally done by means of struts, and redirecting the
air flow through the bypass duct via guide vanes. Choosing
aluminum over titanium and integrating the load carrying and
aerodynamic functions enables a lighter, cheaper design. The
goal of the project was to find a design and manufacturing tech-
nique that would decrease the design weight and radically bring
down the product cost without jeopardizing the integrity of the
IMC. An extensive study in aluminum alloys and manufacturing
techniques was performed, design proposals were developed
and structural analyses carried out. For the first time ever in a
VAC Sirius project three full-scale prototypes were manufactu-
red to verify the computer-aided structural analyses.
A manufacturing technique that offers vast cost advantages
over casting titanium was found. The prototypes demonstrated
coherence between simulated and experimental results. As the
manufacturing technique in question continues to develop at a
fast rate, it is likely to be used in production of future OGVs.
Sirius success storiesSirius 2008/09 Product development projects
8
Background
Gestamp HardTech, with headquarters in
Luleå, Sweden, is the world-leading company
for the press hardening technique. Gestamp
HardTech specializes in developing and ma-
nufacturing high-strength safety components
for the automotive industry. The demand for
such components increases as costs for fuel
and raw materials rise.
The growing number of Suburban Utility
Vehicles (SUVs) has lead to higher insurance
claims related to low-speed impacts. Most
of the damage is a result of the mismatch
between bumper heights of regular cars and
SUVs, which causes under and over ride. The
result is that other more expensive parts have
to absorb the impact.
To mitigate the situation and lower repair
costs, the Insurance Institute for Highway
Safety (IIHS) instituted a new low-speed
impact test that tries to mimic the bumper
geometry of an SUV. This causes problems,
because today’s testing equipment cannot
verify bumper functionality during the IIHS
test, thus there is a need for new equipment.
Assignment
The specific task was to develop a new crash
test cart with the possibility to adjust mechani-
cal parameters in order to reach good cor-
relation with most vehicles on the market.
Parameters that were identified as important
are position for centre of gravity, moments of
inertia, suspension spring constant, suspen-
Product Development Process
The team has worked according to the “Sirius
Masterplan of Creative Product Develop-
ment”. In the early stages the group made
many observations and investigated on the
customer’s needs and demands of the final
product. With this information the team could
determine the product characteristics. These
requirements served as a basis for the brain-
storming workshops where new concepts
were generated. The concepts were then
evaluated for their suitability to the product
characteristics. The process of brainstorming
and evaluation was iterated until satisfying
results were achieved. To test the concepts,
Computer Aided Design and Finite Element
Analysis were used. The dynamic behaviour
of the cart was also tested with dynamic simu-
lations in ADAMS.
Gestamp HardTech strives to reduce the weight and increase
the strength of safety products for passenger vehicles. Product
development work is done in close cooperation with the custom-
ers. The company continually collaborates with university stu-
dents to exchange knowledge and experience in these types of
projects.
Gestamp HardTechLighter more cost-effective solutions
Gestamp HardTech invented and developed the presshardening
technology. With this technology Gestamp HardTech can offer
the OEM’s improved solutions in order to meet challenges for
the future in the field of: environmental topics e.g. reduced fuel
consumption, crash protection and cost effectiveness. Our goal
is to remain as the global leader in the field of the pressharden-
ing technology.
Results
The end results were manufacturing drawings
for a fully functional adjustable test cart and
corresponding list of materials with contact
information to potential suppliers. Along with
the drawings, a program instructs the test
engineers as to how they should go about
configuring the test cart to enable the desired
dynamic behaviour.
9
Top row, from left: Petter Ulfberg, Pär Mikaelsson, Filip Berglund
Bottom row, from left: Johan Nilsson, Andreas Lindberg,
Jonas Pavasson Hatta, Mikael Nybacka (coach)
Testing protoype of the air spring.
One of the investigated suspension types.Adjustable air spring used in the test cart.
Early concept of the complete crash test cart.
sion damping constant, track-width and
wheelbase. Additionally, the weight should
be adjustable in the range of 800-3000 kg to
represent all sizes of vehicles. These param-
eters should also be quick and easy to set
and modify. There was also a requirement to
integrate results from the DYNSYS research
project, which aims to model how much iner-
tial energy is transferred to the bumper during
a-low speed collision. At the end of
the project the team should have
delivered manufacturing drawings
for a fully functional crash test cart.
1110
Background
Hägglunds Drives AB is one of the worlds lead-
ing companies in hydraulic drive solutions. The
head office is located in Mellansel, Sweden,
with production and sales offices all around
the world. The company’s product range is
exceptionally competitive at high torque and
variable speeds below 100 rpm. For variable
speeds below 5 rpm the competition is tough-
er from alternative solutions such as electro-
mechanical drives. To face this challenge,
Hägglunds Drives AB in the last year’s Sirius
project performed a concept study on a new
compact hydraulic drive system designed for
this particular market segment.
Assignment
This years Sirius project continues with the
goal to design and manufacture a full-scale
functional prototype that was to be tested and
evaluated at Luleå University of Technology.
Desired features for the new drive system
included efficiency, compactness and a robust
and attractive design that suits the characteris-
tic Hägglunds Drives appearance of high relia-
bility. The design should also minimize the need
for external cooling and piping while simultane-
ously keeping system noise to a minimum. In
addition to the technical system performance
evaluation, the assignment also included cost
and weight evaluations.
Design for manufacture
Throughout the development process the
project group has worked according to the
“Sirius Masterplan”, from idea generation to
finished prototype. Because a full-scale work-
ing prototype was to be built much of the work
was carried out in the mid to late part of the
product development process. The develop-
ment team went through literature studies,
design space explorations and concept design
and finally focused on the detail design phase.
In this stage the concept was transformed into
a product and all the work had to be performed
with the system's manufacturability in mind.
To ensure that the system worked in theory
before being built it was essential that through-
out, accurate dimensioning calculations were
performed. Also, in order to suggest a suitable
oil for the system, a tribology study of oils oper-
ating at elevated temperature was conducted,
after which an appropriate oil was chosen.
Hägglunds Drives AB continuously strives to improve their
Hydraulic drive systems to make them even more efficient.
To be more competitive in the compact, high-torque, low-
power market segment the company worked together with
students from Luleå University of Technology to design an
innovative, integrated electro-hydraulic drive system that
complements their product range.
Results
After thorough concept evaluation of the main
system as well as of the sub systems the team
selected a concept called FCDS; Frequency
Control led Drive System. Compared to
Hägglunds Drives AB’s current compara-
ble drive system the weight was reduced by
approximately 25% while the theoretical total
efficiency was increased to approximately
84-86%. Newly developed features which
make the improvements possible Include a
new control system and a new cooling system
that functions without an external oil tank. This
concept was built as a fully functional proto-
type which was tested and evaluated at Luleå
University of Technology.
The system will also be further tested in
the test laboratory at Hägglunds Drives AB in
Mellansel during 2009 and 2010.
Hägglunds Drives ABMore than an ordinary drive supplier
DUSTIER, DIRTIER, HARSHER, HEAVIER.
The worse it is, the better equipped we are. After
more than four decades of supplying drive systems for
heavy industrial applications, Hägglunds is accustomed to
difficult demands. We provide what you need to get through
the toughest jobs done right – no matter how harsh the environ-
ment or how specialized the tasks
PERFORMANCE, FLEXIBILITY, SECURITY.
Hägglunds unique hydraulic systems – combined with our wealth of
experience – provide advantages no other drive supplier can match.
With Hägglunds drives on your equipment, you gain:
Maximum torque from zero speed
High performance regardless of condition
Precise control of infinitely variable speed
Standardized modules for design freedom
Smaller, lighter, more efficient installations
Superior protection of equipment and processes
HERE, THERE, EVERYWHERE.
A global leader in industrial drive solutions, Hägglunds has
offices in nearly twenty countries and distribution partners in
many more. We are where you are – with short lead times
and fast, comprehensive service that meets you needs.
OUR DRIVE IS YOUR PERFORMANCE.
Torque arm drawing
From left: Carl-Emil Bengtsson, Joakim Winsa, Jimmy Björnström, Jonas Pelli, Björn Backe,
Pär Marklund (coach)
Parker F12
hydraulic
pump
Jonas Pell i and Jimmy Björnström discusses
details in the system layout.
Full-scale functional prototype of
the concept FCDS – Frequency
Controlled Drive System
Hägglunds Drives CB280 hydraulic motor
Detail of Pall UR219 f i ltration unit
12 13
ing to Svensk Bilprovning (the Swedish Motor
Vehicle Inspection Company).
Organization
The team was divided into groups with different
areas of responsibility and expertise. The three
main groups were; chassis, body & ergonomics
and drive-train. Students from different depart-
ments of the university have been involved in
the project to ensure that all the needed com-
petencies were available early in the develop-
ment process.
Since no company supported the project
financially from the start, an important task has
been to recruit suppliers of parts and materials
as well as getting companies to invest in the
project as sponsors.
Results
The vehicle that has been developed is based
around a self-sustaining chassis made out of
carbon fibre and divynicell. A clever combi-
Baldos is the name of a car that is being developed
and manufactured by students at Luleå University of
Technology, LTU. Students at LTU have once again
accepted the challenge to build a vehicle that is as fuel
efficient as possible, as an entry for Shell Eco Marathon
2009. The team will compete in the 25th annual edition of
Shell Eco-marathon. This year’s race takes place at the
EuroSpeedway in Lausitz, Germany.
nation of twill (bi-directional carbon fibre) and
single-directional carbon fibre has resulted in
a chassis that is almost 50% lighter than last
year’s but still more rigid and robust.
The body has been designed with acces-
sibility and robustness in mind. The accessi-
bility has been improved by making it easier
to access the engine compartment and other
areas of the car that might need adjustments
during the competition. The body has also
been given a new access the driver’s com-
partment. The overall impression of the body
Background
Last year, a team from LTU competed for the
first time and placed first in its class. They also
came home with several special prices, includ-
ing the BOSCH technical innovation award.
They competed in the “Urban Concept Group”,
where the vehicles are designed to look as
much as real cars as possible. There are also
rules regarding outer measurements and ergo-
nomics aspects, etc.
Assignment
The goal was to create a vehicle to participate in
the race in early May. Like last year, we were set
to compete in the “Urban Concept Group”. The
key objectives were to make this year’s vehicle
lighter, more robust and also more ergonomi-
cally adapted. Of course, the main goal was
to outperform last year’s winner – ourselves.
As a bonus assignment, one goal was also to
design and manufacture the vehicle so that
it could be registered as street legal accord-
the energy stored in the super capacitor to run
the vehicle.
The vehicle features an on-board network
that controls the combustion engine, the elec-
trical motor, lights, driver’s interface, etc.
All this has resulted in a vehicle that looks
better, feels more robust and is more light-
weight, hopefully will perform even better in the
competition than last year’s.
The team would like to thank all partners
and sponsors that have provided money, parts,
knowledge and time. The project would not
have been possible without you.
More information about the project is avail-
able at www.baldos.se.
From left: Stefan Inglén, Johannes Carlsson,
Henrik Andersson, Per Nilsson, Jens Carlevi (coach),
Fredrik Löfgren
Sponsors 2009
SCANMOULD
CENTEK
KVASER
APC COMPOSIT
LULEÅ KOMMUN
ATMEL
TOOLTECH
SKF
TRIBOLAB
UDDEHOLM
BLUE CHEM
VAC
DIAB
LULEBO
MAGURA
STICKIT
SVENSKA TANSO
EMBEDDED ARTISTS
ELFA
HELLA
NOVIA INDUSTRI
MFT
AXI
EMAG
LESJÖFORS
MELMAC
DALHEMS
STYLINGWEBBEN
has been improved by adding details that
make it look more like a real production car.
An example of the high detail level and finish is
the head- and rear lights. These are integrated
with the body to create a more
sophisticated look.
The interior has been designed
to make the vehicle look and
feel as much like a real car as
possible. All the information
needed by the driver is presented on LCD-
screens placed in the dashboard. The interior
also features a padded driver’s seat that is inte-
grated with the combined roll-bar/firewall. This
makes the seat more than 80% lighter com-
pared to last year.
The drive-train is a serial hybrid with a
highly efficient, four-stroke 25 cc combus-
tion engine that runs on 100% ethanol, mak-
ing it possible to increase the compression.
The combustion engine drives a three-phase
generator that charges a super capacitor that
stores the energy. An electric motor then uses
1514 15
AB Sandvik CoromantAB Sandvik Coromant is part of the Sandvik AB global
industry group, world-leading within each of the business
areas Tooling, Mining and Construction and Materials
Technology. AB Sandvik Coromant belongs to the Tooling
business area and holds a world-leading position con-
tinuously striving for improvement within development
and manufacturing of cutting tools. With headquarters in
Sandviken, Sweden, the company is represented in more
than 130 countries word-wide. AB Sandvik Cormant has
long been synonymous with innovation and helping cus-
tomers increase productivity and profitability.
position, continuously working to improve
development and manufacturing of cutting
tools.
Assignment
The project has a focus on drilling tools and
the task involves developing an integrated
adjusting device for the peripheral insert on
an indexable drill. This device will make it
possible to get a closer hole-tolerance with
an indexable drill, which today is seen as a
roughing tool. The adjusting device should
assure rigid, precise and strong fastening but
still permit an easy change of drill diameter.
This is a challenge, since the cutting forces on
the cutting edge of such a tool are very high.
Design Process
The project was carried out according to the
Sirius Masterplan. The first step was to gather
information about customer needs and com-
peting solutions. With the gained knowledge
as a base the specification of requirements
was set. The next step was to generate ideas
and concepts that could satisfy set require-
ments. Through continuous brainstorming
sessions and workshops the ideas were
developed and improved into a number of
concepts. The final concepts were evaluated
through Pugh-matrices and FE-simulations.
Result
The strongest concept was further developed
through detailed design. The main benefits of
this concept are that it is feasible to implement
on small drill dimensions and has a good gear
ratio. After thorough calculations and analysis
a full-scale, fully functional prototype was
made and then successfully tested at Sandvik
Coromant.
Together with AB Sandvik Coromant the students have
developed an integrated adjusting device for indexable
drilling tools, to enable an adjustment of the peripheral
insert. This will make it possible to achieve a closer hole
tolerance.
Introduction
AB Sandvik Coromant strives to continuously
improve and develop its tools in order to pro-
vide customers with the best products on the
market. In the 2009 Sirius project the students
have designed an adjusting device for index-
able drilling tools, resulting in more versatile
tools.
Background
Manufacturing companies all over the world
face the same problem – the widening gap
between what the market is willing to pay and
the cost of production. Bridging this gap is
the only way to competitive, and this is how
Sandvik Coromant helps its customers.
AB Sandvik Coromant holds a world-leading
Top row, from left: Emma Rydh, Mojgan Mohseni, Lu Juan Juan, Rebecca Andersson,
Anna Söderlind. Bottom row, from left: Tomas Furucrona, Per Mattson, Jens Hardell (coach),
Peter Åström (coach), Magnus Persson
CoroDrill® 880
Juan Juan Lu looking at
a 3D printout of the final
concept.
CAD model of CoroDrill® 880
17
The global trend of transportation has increased
ever since the first civil aircraft were introduced.
Today, new environmental regulations and demands
combined with an aging and nearly obsolete fleet of air-
craft puts extra focus on the world’s aviation industry.
Volvo Aero Corporation (VAC) is developing and manu-
facturing new and complex structures for today's and
tomorrow's aircraft engines. One of these structures is
the Turbine Rear Frame (TRF).
The challenge was to present a concept
solution well adapted for the requirements
and flexible enough to adjust for tomorrow’s
requirements and new engine types.
Method
Early on, different brainstorming techniques
were used to generate a lot of different con-
ceptual ideas. Together with Volvo Aero these
ideas was narrowed down and enveloped
to a few concepts for further investigation.
To ensure that the requirements for these
concepts could be met, digital mock-ups of
Volvo Aero develops and produces components for commer-
cial aero, military aero and rocket engines with high technol-
ogy content, in cooperation with the world's leading aero
companies. Service and maintenance is an important part of
our operation. Volvo Aero offers an extensive range of service,
including maintenance, repair and overhaul of aero engines
and industrial gas turbines, sales of spare parts for aero
engines and aircraft as well as sales and leasing of complete
engines and aircraft.
Volvo Aero
pollution by 50 percent.
One way to realise the ACARE vision
is to redesign the aircraft and the engines. As
a consequence, the TRF needs to be made
lighter while increasing the aerodynamics and
without affecting the robustness of the prod-
uct.
Assignment
The aim of this project has been to design a new
conceptual TRF with separated functionality.
The final design needed to be well adap-
ted for large-scale manufacturing and in
line with the project constrains, as a cost,
aspect,material limitations due to strength,
thermal resistivity and vibrations.
Background
The environmental demands on the aviation
industry are higher than ever.
These demands affect the entire industry;
from in-air management to manufacturers and
subcontractors.
Experts say emission levels are falling by
an average of two percent every year as older
aircraft are replaced by more fuel-efficient
ones. The Advisory Council for Aerospace
Research in Europe has set the industry three
main targets for 2020.
The ACARE aims to cut the CO2 emissions
per passenger kilometre by 50 percent based
on the average level in the year 2000. The goal
also includes reduction of oxides of nitrogen
(NOx) by 80 percent and to reduce noise
the concepts were created using CAD and
Finite Element Analysis preformed to evaluate
the mechanical properties.
An important part of the project was to
manufacture a prototype that also proved to be
important for the evaluation of the manufactur-
ing aspects of the project.
Project progress was reported on a regular
basis to Volvo Aero, throughout ordinary phone
meetings but also by using and testing Volvo
Aero’s new software for distributed collabora-
tive engineering, the Volvo Teamplace.
Result
One concept was finally selected for deep
investigation and detail design. The concept
was analyzed and a full-scale prototype of a
sector of the TRF was manufactured.
In May 2009 the final concept was present-
ed together with full documentation and a well
explained manufacturing method.
16Top row, from left: Erik Åström, Stefan Sandberg (coach), Elin Söderström,
Andreas Pahkamaa. Bottom row, from left: Johan Holmqvist, Andreas
Gustafsson, Fredrik Forsberg, Erik Hjort, Johan Olofsson
Turbine Rear Frame from the ANTLE-program. Fredrik Forsberg and Erik Hjort
participating in a creative session.
Conceptual design-sketch of a TRF with separated functionality.
CAD-model of a TRF section.
1918
Volvo CE produces the world's best articulated haulers. To keep that
position, continuous R&D is required to give the machines cutting-
edge technologies that are competitive on the world market. This
year the Sirius project team helped Volvo CE with the development
of an all-new drop box. The project goals are to improve the trans-
mission in Volvo’s articulated haulers; reducing wear and tear
and fuel consumption while increasing maneuverability.
Assignment
A transfer case is basically a differential gear-
box that divides the engine torque between
the front and rear wheels. A basic differential
lacks the ability to control torque distribution,
an important factor for good traction. A locked
differential, however, results in wind-up torque
that leads to increased wear. Because of this,
the entire driveline has to be over-dimensioned.
The new transfer case therefore needs to have
the ability to dynamically adjust the torque dis-
tribution.
Background
Volvo Construction Equipment is a subsidiary
of the AB Volvo group, producing a wide range
of construction equipment including the articu-
lated hauler product line. Articulated haulers
are machines made for transporting loads over
rough terrain. The combination of all-wheel-
drive, the rough environment and a total weight
of nearly 80 metric ton sets high demands on
the driveline. One of the central parts of the
driveline is the transfer case.
Volvo CE – More Care. Built in.
Method
The group worked in accordance with Volvo’s
Global Development Process, GDP, which is a
guide for product development. The process is
divided into phases separated by “gates” that
require certain results to be achieved before
passing onto the next phase. The first step
in the process was to come up with different
ideas. After a series of brainstorming sessions,
a few concepts were picked out for further
investigation. From these suggestions a final
concept was chosen.
A concept prototype is not really useful if
it is impossible to manufacture. Therefore,
a production group made a business case
based on the concept for the transfer case.
They investigated what it would take to get
the new transfer case into serial production
in Volvo’s factory in Eskilstuna.
Top row, from left: Andreas Larsson, Magnus Brännström, Patrik Kuoppa
Second row, from left: Nils Hagström, Bertil Hagqvist, Henrik Lundh,
Pär Marklund (coach). Bottom row, from left: Emil Larsson, Johan Kettunen,
Lilian Sunna, Mikael Håkansson, Petter Kyösti
Above: Various creative tools used for concept generation and demonstrations.
Below: Drop-box casing.
Right: Volvo's largest hauler, the A40.
Rendering of the new drop-box casing design.
Articulated hauler power train. The drop-box is placed
to the right of the front axel and left of the brake disc.
A situation where 6 wheel drive and lockable differentials are useful.
Volvo CE, established in 1832, is a subsidiary of the AB Volvo
group with sales in 2007 representing 19% of group turnover.
Volvo CE is a global producer of a number of types of construc-
tion equipment with over 150 models in their present assort-
ment. This assortment includes articulated haulers, wheel
loaders, excavators, motor graders and many other types of
equipment.
Quality, Environmental Care, and of course, Safety are
the three core values of Volvo CE. These cornerstones are
always in focus when developing new products.
Results
A full-scale prototype, a demonstrator, was
constructed. The fully functional prototype will
be tested in one of Volvo’s haulers in summer
2009.
21
The main driving forces behind research at
the Division of Computer Aided Design are
total lifecycle commitment, the extended
enterprise settings, issues of sustainability,
ecology and economy, and – of course –
added value. At the division, we work within
multiple business models that include tradi-
tional transactions, business partnerships,
and extended enterprise models.
Three of these issues are closely linked
to the Sirius course; they are sustainability,
ecology and economy. Developing sustai-
nable systems in the various Sirius projects
directly translates to ecological products as
well as to industrial and economic growth.
Sirius Sustainability
One example is the Hägglunds Drives project.
In the Hägglunds Drives project, by develo-
ping a total integrated system with higher
efficiency, a smaller system can be installed
for the customer, and a smaller, more efficient
system requires less power, thus costing less
to operate and resulting in less environmental
impact. Higher efficiency means fewer los-
ses, which translates to monetary gains for
Hägglunds Drives AB as well as their custo-
mers, creating a win-win business situation.
In the aeronautics industry, for which
the Volvo Aero project is being conducted,
there are ambitious aims to create lighter,
more fuel-efficient and eco-friendly aircraft.
In such a context, arguments about sustaina-
bility, ecology and economy also apply;
perhaps even more so, due to stringent
governmental noise and pollutions require-
ments.
Another, less directly industry-oriented
example is the Shell Eco Marathon project,
where the whole approach aims at develo-
ping and demonstrating eco-friendly techno-
logy, supporting the development of future
environmentally sustainable vehicles.
Finally, in the Sandvik Coromant project,
in which the students have worked on tool
design, the results will be used to support
future AB Sandvik Coromant business sce-
narios. The right tool-interface design speeds
up tool exchange, increases productivity and
thus supports economic development. The
approach allows for more reuse of tools and
tool fittings, and thus a system with higher
sustainability.
20
The Faste Laboratory Centre for Functional Product Innovation
In June 2006, Luleå University of Technology
and the Division of Computer Aided Design
in collaboration with the Division of Fluid
Mechanics, the Division of Mechanics of Mate-
rials, the Division of Solid Mechanics and the
Division of Entrepreneurship were informed
that VINNOVA, the Swedish Agency for Inno-
vation Systems, had granted the application
to start a Vinn Excellence Centre. The
Centre, named The Faste Laboratory, is in
memory of Rolf Faste, Stanford University.
The centre’s goal is to realize Functional Pro-
duct Innovation through research and educa-
tion in collaboration with both academia and
industry. Research and education are joined
in the Sirius course.
Industrial partners are:
• AB Sandvik Coromant (SC)
• BAE Systems Hägglunds (BAE)
• Gestamp HardTech AB (GHT)
• Hägglunds Drives AB (HD)
• LKAB (LKAB)
• Volvo Aero (VA)
• Volvo Car Corporation (VCC)
• Volvo Construction Equipment (VCE)
22
The Faste Laboratory opened formally on
12th March 2007 and had by the end of
stage one, with additional funding, produced
over 100 publications in total. Due to the suc-
cessful first stage of the Faste Laboratory,
on 27th November 2008, the industrial part-
ners together with Luleå University of
Technology agreed upon continuing the re-
search in stage two starting in January 2009.
Functional Product Innovation A perspective of sustainable society forces
industrial development into new ways of con-
ducting business. For manufacturing com-
panies, a way forward is to develop physical
artefacts to provide functions that can be sold
as services. A long-term service contract
means that the provider is responsible for
delivering these functions throughout the life
cycle of the product. The product provider is
responsible for all costs for developing, manu-
facturing, supporting and continuously upgra-
ding the product. Hence, how to reengineer,
reuse and recycle the prduct becomes
important.
The vision of the Faste Laboratory is:
New methods and tools have been develo-
ped enabling functional products with opti-
mized lifecycle cost and customer value.
Central in this mission
are insights into these areas:
• Functional Product Development – contribu-
tes to the area of new processes for engine-
ering design. Closely related to the concept of
Knowledge Enabled Engineering, i.e. sharing,
managing and using knowledge related pro-
ducts and processes throughout the entire life
cycle.
• Distributed Collaborative Engineering – con-
tributes to the area of enabling, in work and
technical oriented terms, design teams to work
closely together by means of methods and
tools.
• Simulation Driven Design – contributes to
bringing several perspectives (e.g. business,
engineering and production) into early concept
design in product development.
Professor Lennart Karlsson,
Division of Computer
Aided Design and
the Faste Laboratory,
Luleå University of
Technology
Funded by the Kempe Foundations and
the Knut and Alice Wallenberg Foundation,
a research studio was designed and built at
LTU. This studio will provide unique access to
empirical studies, testing and evaluation of new
methods and tools in distributed work. The use
of the studio will contribute to research within
the Faste Laboratory.
“The Faste Laboratory at Luleå University
of Technology is one of our strongest research
environments. The close collaboration between
industry and academia within the centre is cru-
cial in order to achieve state-of-the-art results,
to improve industrial best practise, leading to
sustainable growth.”
The Figure illustrates how the Faste Laboratory supports the process from market
needs to FPI. In order to assume a total life-cycle commitment for a functional
product, large company networks i.e. extended enterprises, are needed where
the business risk is shared. The figure further shows the required innovative
capabilities needed for FPI.
Industry and academia in collaborationLars-Ola Normark
Sirius Engineer 2001/02
Volvo Aero Corporation
For me, the Sirius experience was a perfect match. During
the fourth year of study, I felt the need to connect all the
theory to something more business oriented, with all the
new constraints that follow. Being a long-time aviation
enthusiast, it was an obvious choice when I got the oppor-
tunity to work closely with Volvo Aero in developing a jet
engine component.
The experience took the team through the complete
development cycle. Now, following 7-8 years of working in
the aerospace business, I am still amazed at how well the
course reflected the actual product development cycle at
Volvo Aero. A clear sense of professionalism pervaded the
entire programme, both from an academic standpoint and
from the company Volvo Aero Corporation.
Sirius led further to my master thesis at Volvo Aero and
subsequently to employment. I had the great opportunity to
start out as a trainee, where I got to know both the company
and its partners worldwide. In my current role as a lead
structural engineer, I work with the development of new effi-
cient products for the industry. Reflecting over my current
scope of work, it is quite interesting that I now on a day-to-
day basis work with tasks essentially the same as I did dur-
ing the Sirius programme.
Per Söderberg
Manager Research
& Advanced Engineering
Volvo Construction
Equipment AB
Volvo CE has a long history of collaboration with LTU in
different forms including a good number of successful
recruitments and involvement in common research projects.
During 2008/2009 we will also be involved in the Sirius
project. This increased involvement is based on our strong
belief that collaboration between industry and academia will
be a critical factor in the successful provision of knowledge
and competence in the future. We also see the potential for
small, incremental as well as larger, significant innovations
spawning from the Sirius project due to the “out-of-the-box”
creative thinking the students bring to the industrial case.
An additional “win-win” situation that we noticed early
on in the project is that while the real case environment pre-
pares the students for their first job experience, the Volvo
staff connected to the project also receive effective on-the-
job training. We develop our own competence, for example,
by learning more about distributed collaboration and how
to specify work scopes to external R&D sites. Based on this
we already regard our involvement in Sirius as a success
and we hope that the Sirius project will also in the future
be a key ingredient in Volvo CE’s strategy for long-term
competitiveness by creating innovative solutions, develop-
ing people and enhancing competence on all educational
levels.
23
Kajsa Björn
Sirius Engineer 2007/08
Etteplan Industry
Sirius is not a course you take; it’s a course you live.
The commitment, cooperation, inventiveness, and the
knowledge that the students have, give, and earn lack
comparison. Theories and methods are developed into
reality and the goal to finish the project successfully soon
becomes much more important than grades.
Being a part of the successful university-embracing project
“Baldos” did not only give knowledge in designing an
incredibly fuel-efficient vehicle and all the challenges it led
to. Baldos presented challenges when bringing various
opinions and experiences towards a common goal; when
prioritizing between time, cost, and complexity to solve all
possible problems in an effective and sustainable manner.
A good conclusion would be “thinking outside the box”.
What makes Sirius unique are its width and its similarity
to real projects in working life – everything from technol-
ogy, planning, and business dealings is managed by the
students. On a personal level, Sirius made me more self-
confident and increased my self-esteem, the other students
and I were put to constant challenges and were trained to
recognize our own strengths and weaknesses.
Today I work as a technical consultant at Etteplan,
where the ability to adapt to different situations and groups
is essential. To me, Sirius isn’t over, the benefits are for life.
Martin Jonsson
Manager Research & Development
Gestamp HardTech AB
Gestamp HardTech has a long history of advanced research
activities together with Luleå University of Technology.
One example is the DYNSYS research project, where
the goal is to develop dynamic CAE sub-models with good
correlation with full vehicle simulation and crash testing of
bumpers. After an extensive research programme including
test cart and full vehicle crash testing, full vehicle simula-
tions and theoretical modelling an advanced dynamic sub-
model has been implemented.
Still, there was a competence gap that needed to be
closed; our old test cart is totally stiff and cannot repeat
the dynamic behaviour of the crash simulation. The Sirius
student team took the challenge to develop and design an
advanced test cart with adjustable dynamic behaviour.
The engineering task has been solved in a very good
way and the advanced dynamic test cart will soon be built.
It will be the first of its kind on the market and a very impor-
tant tool for our bumper development team.
The Sirius programme has been a new and very posi-
tive experience for us. We will certainly continue with new
projects.
Industry and academia in collaborationFOTO: ATELJÉ GRODAN, LULEÅ
Sirius students 2008/09
Top row, from left: Carl-Emil Bengtsson (HDAB), Emil Larsson (VCE), Nils Hagström (VCE), Per Nilsson (Eco Marathon), Petter Ulfberg (GHT), Jens Hardell (coach), Andreas Pahkamaa (VAC), Jens Carlevi (coach), Johannes Carlsson (Eco Marathon),
Stefan Sandberg (coach), Magnus Karlberg (Coordinator), Magnus Löfstrand (coach)
Second row, from left: Björn Backe (HDAB), Andreas Lindberg (GHT), Joakim Winsa (HDAB), Pär Marklund (coach), Henrik Andersson (Eco Marathon), Bertil Hagqvist (VCE), Per Mattson (SC), Magnus Persson (SC), Mikael Håkansson (VCE),
Fredrik Forsberg (VAC), Henrik Lundh (VCE), Patrik Kuoppa (VCE), Peter Åström (coach), Tomas Furucrona (SC)
Third row, from left: Pär Mikaelsson (GHT), Erik Åström (VAC), Jonas Pelli (HDAB), Emil Larsson (VCE), Johan Kettunen (VCE), Fredrik Löfgren (Eco Marathon), Andreas Gustafsson (VAC), Petter Kyösti (VCE), Johan Olofsson (VAC), Johan Holmqvist (VAC),
Filip Berglund (GHT), Lennart Karlsson (Professor)
Bottom row, from left: Johan Nilsson (GHT), Jonas Pavasson Hatta (GHT), Mikael Nybacka (coach), Elin Söderström (VAC), Mojgan Mohseni (SC), Anna Söderlind (SC), Lu Juan Juan (SC), Lilian Sunna (VCE), Rebecca Andersson (SC), Emma Rydh (SC),
Jimmy Björnström (HDAB), Erik Hjort (VAC), Magnus Brännström (VCE)