Light Weighting

Webinar - Development of a Manufacturing Process for High-Power Density Hollow Shafts. Researchers Professor Gracious Ngaile and Doctoral Candidate Hao Pang discuss the FIERF sponsored research conducted at North Carolina State University on the feasibility of forging hollow axle shafts and pinion gear shafts for light weighting in the automotive industry.

Modelling of the Forging Process for a Magnesium Alloy Automotive Control Arm”, Talal Paracha Thesis presented to the University of Waterloo in fulfillment of the thesis requirement for the degree of Master of Applied Science in Mechanical and Mechatronics Engineering 2018.

Talal Paracha Thesis presented to the University of Waterloo in fulfillment of the thesis requirement for the degree of Master of Applied Science in Mechanical and Mechatronics Engineering 2018.

The automotive industry has placed significant emphasis on weight reduction to achieve better fuel economy while maintaining safety and quality standards. One way this can be achieved is by using forged magnesium alloys due to their high stiffness- and strength-to-weight ratios.

Development of a Manufacturing Process for High-Power-Density Hollow Shafts, Hao Pang, Research Assistant and Gracious Ngaile, Professor, North Carolina State University, Department of Mechanical and Aerospace Engineering, May 2019 Final Report

This FIERF supported research presents a new method for forging hollow shafts for power transmission. This method consists of three main operations; selective heating of a tubular workpiece, upsetting of the workpiece to produce a solid section in the heated section and, flanging or heading of the hot solid portion of the tubular workpiece. FEA and experiments were carried out to determine the feasibility of the process.

Weight Reduction Finite Element Study of Selected Power Train Components for Heavy Duty Vehicles, James Lowrie, Research Assistant and Gracious Ngaile, Associate Professor, North Carolina State University, Department of Mechanical and Aerospace Engineering, April 2016

Final Report – Study on Weight Reduction of Forged Parts used in Heavy Duty Vehicles via Innovative Forging Techniques and Material Substitution, James Lowrie, Research Assistant, Hao Pang, Research Assistant and Gracious Ngaile, Professor, North Carolina State University, Department of Mechanical & Aerospace Engineering, May 2016

Bimetallic Axle Preform Development for Heavy Duty Truck Weight Reduction, Vanessa Martin-Wegryn, Undergraduate Assistant, Ross Crowley, Research Assistant, Dr. Joseph Domblesky, Professor, Marquette University, Department of Mechanical Engineering, May 2017

Webinar Part I; June 27, 2017 – Weight Reduction of Forged Parts in Heavy Truck Vehicles

Webinar Part II; July 6, 2017 – Weight Reduction of Forged Parts in Heavy Truck Vehicle

Survey of Forgings Used in Heavy Duty Vehicles and Potential Methods for Weight Reduction