Utveckling och validering av en oljekoppling för turboaggregat

Abstract

This bachelor’s thesis, conducted in collaboration with Volvo GTT, aims to develop an alternative design proposal for an oil connection to the turbocharger housing. The project was initiated to develop a component that is easier to assemble, has lower complexity, and reduced lead time. The existing solution is functional but suffers from high material consumption and complicated assembly, which motivates a new design. The work follows a systematic product development methodology, beginning with a market analysis and a technical review of the current solution. Tools such as brainstorming, elimination matrices, Pugh matrices, and Kesselring matrices were then used to generate and screen concepts. The final choice fell on a simple, robust design that seals through metallic deformation during assembly. CAD models and technical drawings were developed according to ISO standards and Volvo’s internal guidelines. The selected material was austenitic stainless steel due to its high hardness and temperature resistance. Alternative materials such as ferritic steel were also considered as potentially more cost-effective options. A validation plan has been developed, including pressure, vibration, and salt tests, as well as thermal cycling. Finite Element Method (FEM) simulations were conducted to analyse contact pressure and plastic deformation in the seal. The results indicate that the load is absorbed as expected, but further simulations are recommended. For continued development, physical testing, FMEA updates, and economic and environmental analyses are proposed. In addition, a dialogue must be established with suppliers and Volvo GTO in Skövde. The project has delivered a proposal for an improved oil connection with the potential to streamline production and reduce costs while maintaining functionality and durability.