Analysis and Optimization for the Production Process of an Automotive Alternator Using FEM and Experiments

A. D'Annibale; Antoniomaria di Ilio; M. Trozzi; L. Bonaventura

doi:10.4028/www.scientific.net/KEM.639.395

Paper Titles

Investigation on the Strain Behaviour of a Precipitation-Hardenable Aluminium Alloy through a Temperature Gradient Based Heat Treatment
p.361

Identification of Plasticity Model Parameters of the Heat-Affected Zone in Resistance Spot Welded Martensitic Boron Steel
p.369

Influence of Stress Relaxation after Uniaxial Pre-Straining on Subsequent Plastic Yielding in the Uniaxial Tensile Test of Sheet Metal
p.377

Validation of Kinematic Hardening Parameters from Different Stress States and Levels of Plastic Strain with the Use of the Cyclic Bending Test
p.385

Analysis and Optimization for the Production Process of an Automotive Alternator Using FEM and Experiments
p.395

Experimental and Numerical Investigation on a Pressure Dependent Friction Model
p.403

A Constitutive Model for the Simulation of the Deformation Behavior of TWIP Steels
p.411

Numerical Prediction of Failure within Small Curvature Bending of Advanced High Strength Steels
p.419

Enhancement of Lemaitre Model to Predict Cracks at Low and Negative Triaxialities in Sheet Metal Forming
p.427

HomeKey Engineering MaterialsKey Engineering Materials Vol. 639Analysis and Optimization for the Production...

Analysis and Optimization for the Production Process of an Automotive Alternator Using FEM and Experiments

Abstract:

This paper presents the analysis and the optimization of the process parameters for an innovative and more efficient production system for claw pole alternators intended for automotive application. The authors, after a preliminary study about forces, material properties and geometrical specifics to achieve, set out a first set of parameters to realize an 8-pole rotor. After that, it was possible to layout each step of the forging process in a FE model and observe the geometrical properties of the final rotor. Once reached a good comprehension of the whole process by preliminary studies, experiments were conducted with the effective material currently employed to build the claw pole and other information were collected to refine the finite element model. By comparing the results between the FEM and experiments, it was possible to build a realistic model, which allowed adjusting the process in short time in order to make the final product meet all the required geometrical specifics and pass the electrical tests.

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Periodical:

Key Engineering Materials (Volume 639)

Pages:

395-402

DOI:

https://doi.org/10.4028/www.scientific.net/KEM.639.395

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Online since:

March 2015

Authors:

A. D'Annibale*, Antoniomaria di Ilio, M. Trozzi, L. Bonaventura

Keywords:

Automotive Alternator, Finite Element Simulation (FEM), Sheet Metal

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