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ADVANCED POWERTRAIN COMPONENTS
NETFORM - Advanced metal powertrain components for all industries... At NETFORM, all our products are uniquely tailored to a specific application or problem. They result from detailed technical discussions with our customers, where problems are discussed and solutions brainstormed together. This allows us to create a product ideally suited to the application - lighter, stronger and cost effective. Feel free to contact us - let us help you solve your problem...
KEY
ADDITIONAL INFORMATION
ELECTRIC HYBRID ICE (Internal Combustion Engine) FUEL CELL
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TABLE OF CONTENTS WELCOME.....................................................................4 - 5 WHO WE ARE..................................................................6-7 WHAT IS COLD FORMING?...............................................8 - 9 WHAT IS FLOWFORMING?............................................. 10 - 11 PRODUCT GUIDE.........................................................12 - 55 ROTOR SHAFTS......................................................16 - 25 STATOR HOUSINGS............................................... 26 - 33 FLOWFORMED DIFFERENTIAL CASES...................... 34 - 35 HYBRID P2 ROTOR CARRIER................................. 36 - 37 LIGHTWEIGHT CARRIER ASSEMBLIES...................... 38 - 39 COLD-FORMED SPLINED HUBS...............................40 - 41 FLOWFORMED CLUTCH DRUMS............................ 42 - 43 FLOWFORMED CARRIER SHELLS............................44 - 45 COLD-FORMED PINION CARRIERS......................... 46 - 47 ADVANCED PINION CARRIERS...............................48 - 49 BI-DIRECTIONAL HUBS.................................................50 PARKING PAWLS.......................................................... 51 DIESEL ENGINE CROSSHEADS......................................52 TORQUE CONVERTER LUGS..........................................53 VALVE RETAINERS........................................................53 MISCELLANEOUS PARTS......................................... 54-55 QUALITY & CERTIFICATIONS.......................................... 56-57 REDESIGN GUIDE......................................................... 58-65 PLANETARY CARRIER.............................................. 60-61 CARRIER ASSEMBLY................................................62-63 SPLINED HUB........................................................ 64-65 CONTACT.....................................................................66
WELCOME Creativity and Innovation - two key reasons that NETFORM is an industry-leading manufacturer of advanced cold-formed powertrain components. The requirements for all Tier 1 automotive suppliers are the same - unerring quality and on-time delivery at pricing acceptable to the customer. So how does a company differentiate itself...? In our case, it is by tying a passion for both product and process development to the ability to listen and understand your challenges. Working closely with your engineers - as early as possible in programs - we thoroughly review the part/assembly/issue. After identifying key surfaces and features required, we then generate ideas and opportunities for part consolidation, weight reduction, cost savings etc. In the following pages, you will see examples of the many products we have developed for our customers. This is our history. Our future parts may look very different, but they will be based on the same principles – understanding the issue, brainstorming options and creating innovative solutions. So please, feel free to contact us – we would love to help you.
President
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NETFORM AT A GLANCE 150 Employees Plants in Michigan & Ohio
Automotive, Agricultural, Industrial markets supported
Customers on 4 continents
TRUSTED BY
AND MANY MORE!
IATF16949 | ISO9001 ISO14001 certified
WHO we are... NETFORM is a leading manufacturer of cold formed components used in many different industries, with a strong focus in the powertrain arena.
MAUMEE, OHIO
PRESS-BASED COLD FORMING CENT 100,000 SQ. FT. •Cold Forming •Coining •Coating •Deburring
TER
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SHELBY TOWNSHIP, MICHIGAN
MAUMEE, OHIO
FLOWFORMING & MACHINING CENTER
PROTOTYPING & TOOLING CENTER
55,000 SQ. FT.
10,000 SQ. FT.
•Flowforming
•Balancing
•EDM
•Turning
•Turning
•Deburring
•Milling
•Grinding
•Milling
•Drilling
WHAT IS COLD FORMING?
Cold forming (also called cold forging or coining) is a process where material is transformed into new shapes at room temperature in high-tonnage presses. Using a combination of a metal preform, special tooling and mechanical presses, unique complex components can be formed. Where cold heading is typically used to produce bolts/rivets etc, cold forming at NETFORM is used to produce powertrain components such as planetary carriers and splined hubs. Cold Form Process Video
WHY COLD FORM?
One of the major benefits of cold forming is work hardening. This strength increase allows the thinning down of equivalent stamping or forging cross sections, saving weight while not impacting strength. Alternatively, for the same packaging constraints, a stronger part can be produced. This work hardening can also allow the elimination of hardening heat treatments. Part surface quality often can be used as-formed.. Cold forming also allows variable part cross-sections. This in turn provides opportunities for part consolidation.
DESIGN FOR COLD FOR
Cold-formed components at NETFORM are formed by taking metal preforms and extruding them in knuckle joint presses. Th form of extrusion activity allows the parts to be designed with varying cross sections:
Variable cross sections possible
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RMING
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The NETFORM cold forming process allows features to be provided in the component as-formed. Below is an example of an as-formed oil groove:
The movement of the material during the press-based forming stroke results in cold working and grain refinement. The end result is an increase in material strength 2-3 times the base material: 250
YTS(MPA)
UTS(MPA)
625 450 700 0
100
200
300
1020 ANNEALED
As-formed oil groove
400
500
600
700
1020 COLD-FORMED
Strength Increase
REDESIGN INITIAL DESIGN
•Formed from imported tube. •1 minute process. •$4M capital investment made by customer.
REDESIGNED •Formed from a flat blank - single hit. •10 second process. •Over $2 savings per part.
WHAT IS FLOWFORMING?
Flowforming is a cold rotary forming process where a rotating metal preform is formed over a tool by (typically) three rollers. The rollers deform the preform, forcing it against the tool (also known as a mandrel), axially lengthening and radially thinning the material. The material will take on the reverse profile of the mandrel, allowing the forming of features such as splines and piston seal surfaces. Flowform Process Video
WHY FLOWFORM?
Flowforming is an extremely effective way of manufacturing net-formed splines, with minimal material wastage. These splines have uninterrupted grain paths that have higher toughness than typical cut splines, along with zero porosity concerns. The high level of material deformation during the forming process creates significant work hardening. This can allow for elimination of heat treatment on the splines. With the correct selection of preform, part consolidation and weight reduction are possible.
FLOWFORMING PREFO
One key factor for effective flowfo drums is the correct selection of preform. Options include flat blanks, hot forgings, stampings and cold forgings.
NETFORM has developed its own unique process for cold forming hu on flowform preforms. This proces shown below: Hub Forming Process Video
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ORM SELECTION
orm
The benefits of this process include: •Consolidation of 2 parts to 1. •Elimination of laser welds and induction hardening.
•Work hardening in the hub area from the cold forming process. •Ability to have right angle joints at the hub/drum interface not possible with stampings.
ubs ss is
Example of NETFORM hub forming process (single hit)
REDESIGN INITIAL DESIGN •3-piece design. •5 lbs weight. •Drum back face material not used in final assembly.
REDESIGNED •2-piece design. •3 lbs weight. •Drum back face material utilized in final assembly.
NETFORM PRODUC
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CT GUIDE
POWERTRAIN’S EVOLVING FUTURE...
The future of the powertrain industry is more uncertain today than ever before. The range of options - from ICE to hybrid to EV to fuel cell - is large and the direction of the industry is still to be determined. Accordingly, NETFORM’s product range is designed to cover all of these areas. The following key indicates which type of powertrain the components apply to.
ELECTRIC HYBRID ICE FUEL CELL
POWERTRAIN PRODUCTS FOR ALL POWERTRAIN SOURCES NETFORM’s product range applies equally to all three major powertrain areas – internal combustion engines (ICE), hybrids and EV’s. These products all share the same common philosophies: •Unique products & processes. •No “build to print” activities. •Parts consolidation wherever possible. •High value, high margin products. •Use of patents where possible.
ICE
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EV HYBRID
ROTOR SHAFTS Electric vehicle powertrains present different mechanical engineering challenges compared to traditional powertrain architectures. These challenges come in many forms, including higher working RPM’s, to lower noise limits, to increased heat transfer capabilities and so on. Rotor shafts have evolved over recent years. Originally solid machined forgings, shafts moved to lighter weight designs through additional center drilling. This in turn evolved to hollow shafts that provide greater weight reduction. The latest step in rotor shaft evolution is to increase their function from solely supporting the laminates, to additional activities such as cooling management or integrated differential gears.
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NETFORM has developed novel manufacturing processes that allow the cost-efficient production of advanced rotor shafts with integral cooling and component consolidation. NETFORM’s Flowforming and Press Forming technologies help overcome the product design limitations that come with using a shaft preform designed from traditional manufacturing processes. Using NETFORM’s advanced forming processes, product engineers can achieve part consolidation, weight reduction, cooling system incorporation and cost reductions not previously possible.
ROTOR SHAFTS - FLOWFORMED
NETFORM’s flowforming approach to manufacturing rotor shafts provides many options for part optimization. With the correct design and manufacturing approach, weight can be reduced and cooling performance increased, while still meeting or beating cost and weight targets. In addition, the usage of a forged preform allows for the incorporation of traditionally-separate components. The key factor is having design discussions (at concept stage) with all parties involved – manufacturing, product engineering, assembly. This way the optimum design can be achieved at the lowest cost.
TECHNICAL INFORMATION
Materials: Low Carbon Steels Diameter: 40 mm min – 250 mm max Max Length: Up to 350 mm Work Hardening: Up to 2-3X original strength. Forming capabilities: Formed Diameters ±0.10mm Tooth Space ±0.05mm Runout between Inside Diameters 0.05mm
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MANUFACTURING PROCESS The flowformed rotor shaft process traditionally starts with a forged blank. The forging is machined prior to the flowforming process, followed by finish machining as required.
Forged Blank
Flowform Process Video
Flowformed
Machined
ROTOR SHAFTS - FLOWFORMED DESIG MULTI-PIECE •Flowformed rotor shaft •Machined cap •Laser-welded
ONE-PIECE ROTOR SHAFT •Flowformed forging •Cooling unit inserted - optional •End “necked” as required
ONE-PIECE WITH COOLING TUBE •Tubular preform •Outer tube reduced, trapping inner tube. •Process repeated to the other end. •Uni-directional coolant flow
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GN OPTIONS TWO-PIECE LONGER SHAFT •Two flowformed shafts •Center weld
Optional
Coolant control cylinders
Optional
Center support
ONE-PIECE WITH INTEGRAL COOLING TUBE •Flowformed forging •Cooling tube inserted •Shaft reduced, trapping tube •Bi-directional coolant flow
DESIGN FEATURES POSSIBLE INTEGRATED TRADITIONALLY SEPARATE COMPONENTS
COOLANT UNIT INTEGRATION
Flowform
Insert
Neck
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HEAT TRANSFER IMPROVEMENTS
Trapped Cooling Fins
Splined ID
KEY WAY DRIVEN WEIGHT REDUCTION
TRADITIONAL SHAFT Typical shaft weight 5 lbs
FLOWFORMED SHAFT Typical shaft weight 4 lbs
ADVANCED TECHNOLOGY
PRESS-FORMED EV ROTOR SHAFTS
Traditional tube thinking is discarded with this method of tube manufacture. Tubes no longer need to be straight with constant wall thickness. Combining advanced stamping technology with special-purpose laser welding equipment, the tube can now become a flexible part of the rotor shaft design process.
U &O Process Video
U &O Process Simulation
DESIGN FLEXIBILITY
This tube forming process allows the product engineer greater design flexibility. Freedom to select the optimum tube material, to design inserts for performance not assembly, to vary tube diameters and thicknesses as necessary - resulting in the generation of a superior finished product.
Patent Pending
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TAILOR-WELDED ROTOR SHAFTS
Tailor-welded blank
U-form
Assembly
Through the use of tailor-welded flat blanks, tubes of varying material and/or thickness are possible.
O-form and laser weld
Heat exchangers can be inserted into the ”U” channel prior to “O” forming and tube welding.
MULTI-DIAMETER ROTOR SHAFTS
Flat blank
U-form
Cutaway tube
O-form and laser weld
STATOR HOUSINGS NETFORM offers three different processes for producing stator housings for EV motors. These include: •Flowformed stator housings •Press-formed stator housings •Rolled & welded fabricated housings Each of the processes has potential benefits, the extent of which will depend on the application being considered. Press-formed Stator Housings •Suitable for housings less than 100m in length •Cost-effective process •One-piece construction Flowformed Stator Housings •One-piece construction •Work-hardened wall Rolled & Welded Fabrications •Suitable for modular applications – common flange, multiple lengths •Flexible production process
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STATOR HOUSINGS - PRESS FORMED Using a unique NETFORM-developed process that combines cold forming and a stamped drawing process, NETFORM can produce stator housings in a single press hit/single station. Starting with a flat ring, the inner material is stretched down to form the main stator body. The fact that the housings are formed in a single tooling station leads to lower tooling costs, when compared to progressive or transfer stamping processes. This single-hit process also provides lower cost engineering changes should they be required.
MANUFACTURING PROCESS •The process starts with a flat, stamped blank. •This blank is loaded into a cold forming press, then stator are walls formed. •The formed part is then finished machined as required.
Blank
Press formed
Machined
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Stator Housing Process Video
TECHNICAL INFORMATION
Materials: Low Carbon Steels Diameter: Up to 500mm Max Max Length: Up to 80mm Work Hardening: Up to 2-3X original strength. Forming capabilities: Potential to pre-machine while in flat state Formed Diameters held as tight as 0.10 mm Faster part to part production and lower tooling cost
STATOR HOUSINGS - FLOWFORMED
The flowforming process provides increased flexibility for the product engineer. The variety of starting preforms available - flat blanks, stampings, forgings - allows a wide variety of finished components to be designed and manufactured. The process also allows for variable wall thicknesses on the housing, as well as providing a one-piece finished housing.
MANUFACTURING PROCESS The process starts with a blank that could be a forging or a stamping. The preform goes through the flowforming process and is finally machined as required.
Preform
Flowformed
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TECHNICAL INFORMATION Materials: Low to medium carbon steels Diameter: Up to 300mm Max Length: Up to 350 mm Work Hardening: Up to 2-3x original strength. Forming capabilities: Variable cross-sections possible Excellent material utilization Formed diameters held to ±.25mm
Varied cross section
STATOR HOUSINGS - ROLLED & WELDE This process utilizes advanced CNC equipment to offer a fabricated, laser-welded stator housing. This process has excellent material utilization and is well suited where there is a family of similar parts that need to be manufactured on the same program A cut-to-length flat blank is fed into a programmable CNC roller to form the basic tube. This formed component is then precision clamped and then laser welded. The mating flange - which can be laser cut, stamped or fine blanked - is then laser-welded to the tube to form the complete housing.
MANUFACTURING PROCESS The process starts with a rectangular steel blank. The blank is rolled and laser welded. Tube is then end trimmed.
Flat blank
Rolled
Laser weld
Weld flange
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ED DESIGN OPTIONS DUAL WALL
This process allows for the manufacture of dual walled housings. Dual walls can be used to increase cooling performance of the housing.
Stator Housing Process Video
TECHNICAL INFORMATION Materials: Low to medium carbon steels, stainless steel Diameter: Up to 400mm Max Length: Up to 350 mm Forming capabilities: Dual wall capability for optimal cooling Cooling inserts for all diameters/sizes Excellent material utilization
FLOWFORMED DIFFERENTIAL CASES NETFORM has developed a cost-effective solution for lightweight differential cases The flowforming process allows for a lightweight, high strength case from steel instead of the traditional cast iron. Several design options exist to allow the manufacture of a variety of differential types. In addition, clutch packs can be incorporated into the differential as required at minimal additional cost.
Gear interface can be machined as per traditional differential cases.
D
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DESIGN OPTION 1 Flowformed differential case
DESIGN OPTION 2
Laser-welded three-piece steel differential case assembly
Light-weight cold- formed carriers
HYBRID ENGINE P2 ROTOR CARRIER NETFORM has developed a lightweight high-strength P2 rotor carrier for hybrid applications. A laser weld is eliminated and major weight savings achieved by combining two separate stampings into a single, robust component.
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PRODUCT FEATURES KEYWAY Locating the keyway in line with a formed tooth allows for the reduction of the overall carrier wall thickness.
WALL THICKNESS A wall thickness of 2mm-3mm is possible by either moving the clutch spline outwards or the laminate locating diameter inwards.
LIGHTWEIGHT CARRIER ASSEMBLIES Multi-piece cold-formed carriers, laser-welded together, form the basis for high strength carrier assemblies. Available in either the component form, (for laser-welding at the customer) or as a complete assembly, the solution can be tailored to the application being considered.
3-piece laser-welded assembly for high load, off-road application
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2-piece laser-welded assembly
REDESIGN
INITIAL DESIGN
•3-piece hot forgings •Laser-welded •Fatigue life issues
REDESIGNED
•3-piece cold forgings •Laser-welded •Over 2 lbs of weight saving •Improved fatigue life performance
COLD-FORMED SPLINED HUBS NETFORM has developed a unique cold forming process for splined clutch hubs. Hubs are produced with ready-to-use splines and varying cross sections through the utilization of proprietary cold forming technology. These splined components have significant cold working that can eliminate the need for previously planned heat treatments. Our unique process also allows for part consolidation resulting in the elimination of welds, reduction in machining capital, tooling, supply-base activities and warranty issues.
Splined Hub Video
ADVANCED SPLINED HUBS Cold-formed splined hub with integrated orbital riveting stakes.
Cold-formed splined hub with integrated shaft.
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Press-formed hubs with splines formed during the main extrusion process
FLOWFORMED CLUTCH DRUMS NETFORM has developed expertise in the area of flowformed drums for use in powertrain applications. Key product differentiation in this area is through the opportunity to use unique cold forming technology for the production of the preform. This technology can eliminate the need for both heat treatment and laser welding operations. It also allows for part consolidation resulting in the reduction of program capital, tooling, supply-base activities and warranty issues. Flowformed drums are finished machined in dedicated, automated machining cells. An example is shown in the video icon below. Clutch Drum Video
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FLOWFORMED CARRIER SHELLS NETFORM has expertise in the area of flowformed, fully-machined carrier shells. Formed out of 1035 steel, these products are supplied to the customer ready for assembly.
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ADVANCED FLOWFORM DRUMS Flowformed drum with integrated axle shaft
“Trapped” steel gear in an aluminum body
COLD-FORMED PINION CARRIERS NETFORM has manufactured millions of cold-formed carriers for powertrain applications over the last twenty years. These carriers, supplied ready to assemble, incorporate many as-formed features. Cold Form Carrier Video
Cold-formed planetary carriers for automatic transmissions
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MACHINED CARRIERS
NETFORM also manufactures fully-machined powertrain carriers. Processes include broaching, milling, drilling, deburring set up in dedicated machining cells.
ADVANCED PINION CARRIERS The evolving nature of the powertrain industry is driving change at the component level. Products are required that are larger, stronger and lighter than current carriers manufactured. The “tripod” carrier shown allows carriers of up to 8" diameter to be formed. The carrier with stiffening webs is for applications when the stiffness requirements of the part require additional support.
Large diameter tripod
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carrier
Traditional cold-formed carrier with stiffening webs.
BI-DIRECTIONAL HUBS From flat blank to the part shown below in a single hit…
Tight tolerances, low cost tooling and uninterrupted grain flow – a totally unique forming process.
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PARKING PAWLS Parking pawls are traditionally either fine blanked or hot forged with extensive machining. NETFORM parking pawls provide design flexibility, increased strength, and the opportunity for cold-formed key surfaces.
DIESEL ENGINE CROSSHEADS Netform has developed a unique cold forming process for diesel engine crossheads that reduces system costs. The crossheads are cold formed and ready to use. No machining is necessary, with all surfaces being as-formed. Crossheads are also heat-treated to provide the required wear characteristics.
Crossheads Process Video
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TORQUE CONVERTER LUGS
NETFORM provides cold formed torque converter lugs for various powertrain applications. Working closely with the customer, designs are established that allow the parts to be used as-formed. These lugs do not require heat treatment as a result of the work hardening offered by the cold forming process.
VALVE RETAINERS
NETFORM has developed a unique cold forming process for valve spring retainers. The valve retainers are cold formed ready to use. No machining is necessary, with all surfaces being as-formed. Retainers are also heat-treated to provide the required wear characteristics. Over 12 million valve retainers a year are produced, with a long history of zero PPM years and zero warranty claims.
MISCELLANEOUS PARTS The following are some examples of the “traditional” products that NETFORM can provide.
Reluctor Wheel
Brake Caliper Key
Bearing Strap
Seat Rack
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Apply Plate
Support Hub
Inner Plate
Ball Joint Housing
Airbag Canister
Fan Shaft
QUALITY & CERTIFICATIONS NETFORM sets the bar for quality system requirements in the industry. The extensive use of the PLEX ERP system ensures that NETFORM stays in control at all times. Audits are straightforward and common information is available to all employees. NETFORM is proudly certified in IATF-16949, ISO-9001, and ISO-14001.
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IATF 16949
IATF 16949
ISO 14001
ISO 14001
ISO 9001
ISO 9001
REDESIGN GUIDE
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NETFORM REDESIGN PROCESS NETFORM has a unique approach to the design process. NETFORM prefers to work closely with your engineers to thoroughly review the part/ assembly/ issue. NETFORM will then generate ideas and opportunities for part consolidation, weight reduction, cost savings, ect.
NETFORM PLANETARY CARRIER REDESIGN Review by NETFORM of a customer’s early design for a new planetary carrier assembly indicated potential to save both cost and weight. This redesign was implemented and went on to become the customer standard for this product type.
REDESIGN PROCESS
Reviewing the original design, it was realized that the center material of the outer drum was thrown away during that part manufacture, and then replaced with powder metal material in the finished assembly. By redesigning the assembly to utilize that material had two benefits – 1) lower material costs and 2) the ability to now weld the two parts together, eliminating the snap ring and its associated costs.
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ORIGINAL DESIGN •Three-piece assembly •Three component suppliers •Three sets of tooling
COLD-FORMED REDESIGN •Two-Piece assembly •Two component suppliers •Two sets of tooling •Over 1 lb. of weight savings
NETFORM CARRIER ASSEMBLY REDESIGN A customer’s design for a carrier assembly required an improvement in fatigue life. Designs using hot forgings and powder metal failed to provide the improvements required. A NETFORM cold-formed redesign was implemented which saved, weight, cost less while still improving fatigue life.
REDESIGN PROCESS
Reviewing the original design, the customer’s product was redesigned to facilitate the cold forming manufacturing process. To maximize production output, and hence lower costs, a common preform was designed for the three components. Laser welding was used to join the three components and heat treatment added, as necessary.
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ORIGINAL DESIGN •PM carrier •Failed durability requirements
COLD-FORMED REDESIGN •One cold formed preform •2 lbs weight reduction
NETFORM SPLINED HUB REDESIGN A customer was having pricing and manufacturing output issues with a splined hub. This was due to a combination of special tubing from Japan and a very slow (1 minute) processing time per part. NETFORM developed a new process for forming the splines net, addressing both customer concerns successfully.
REDESIGN PROCESS
Stamping from a flat blank for a cold formed hub allowed for immediate cost savings. Development work took place to allow the splines to be formed during the extrusion process. Finally, an engaged customer manufacturing engineer incorporated NETFORM’s process needs into the final part drawing.
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ORIGINAL DESIGN • Formed from tube • Tube imported from Japan • 1 Minute processing time • $4M Capital investment made by customer
COLD-FORMED REDESIGN •One cold formed preform •2 lbs weight reduction
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51810, Danview Technology Court Shelby Township MI 48315
1007, Illinois Avenue Maumee OH 43537
salesgroup@mfccorp.com www.netform.com