Additiv tillverkning av lättviktslösningar för elektrifierade drivlinor

Examensarbete på kandidatnivå
Jaksic, Sandra
Johansson, William
Johnsson, Julia
Jost auf der Stroth, Sofia
Nilsson, Sofia
Palm, Emilia
The automotive industry is facing major challenges to switch from internal combustion engine operation to electric operation, where the conventional engine is replaced by an "e-axle", and transmission as well as power electronics are integrated in a compact solution. Continuing to develop the electric powertrain requires complex solutions, which places demands on today’s traditional manufacturing methods. Additive manufacturing (AM), colloquially called 3D printing, is a manufacturing method that has received much attention in recent years due to its advantageous properties that can create geometrically smart and functional lightweight solutions. The purpose of this study is to visualize how it is possible to apply lightweight solutions to electric powertrains via AM. The aim is also to analyze why AM is not used in greater extent in industries today. The study includes some limitations such as; it will only address AM in metal, the study will only take passenger cars in consideration and specific cost analysis will not be addressed. The report is a literature study and the sources used are scientific articles, journals, books and websites. The discussion analyses whether it is appropriate to use AM on various components in the driveline, which results in it not being useful for larger parts that are exposed to large cyclic loads as it results in fatigue. Smaller components with complex geometries and design requirements, on the other hand, can be manufactured very well via AM. The performance is also discussed, which can be designed via truss structures to reduce noise in the driveline. The effect of reducing the weight of an electric car is both positive and negative, positive when it increases range but negative when regenerative braking gives energy back to the battery and benefits from higher weight. Other aspects of why AM is not used to a greater extent are because of the metal powder being very expensive, the production speed is low and AM is best suited for production in smaller series. The conclusion is that it is possible to create lightweight solutions using AM in metal but it is not always advantageous because of the limitations stated above.
Additive manufacturing , lightweight solutions , electric powertrain , electric drivetrain
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