Hollow shaft concepts in powertrain - potentials for efficiency increase in car operation and car manufacturing

Sustainable action begins with sustainable production. In this context, the driving forces for progress and innovations in production engineering are complemented by another topic: resource efficiency. Examples for strategies and solutions leading to more efficient utilization of resources are the application of efficient technologies or the optimization of process chains by integrating and combining processes. However, using these strategies, not only product manufacturing can be optimized as regards resource utilization. Furthermore, the opportunity arises for saving resources during product operation, i.e. during vehicle operation. Thus the consistent application of strategies of lightweight construction in car body manufacturing leads to a reduction of fuel consumption and finally to a decrease in CO2 emissions. One approach which is gaining more and more importance in the sector of vehicle manufacturing is substituting conventional solid shafts by hollow shafts. Considering the potentials of implementing concepts of hollow shafts in the production and the operation of vehicles for improving resource efficiency, the Fraunhofer Institute for Machine Tools and Forming Technology conducts research activities in this area which plays a major strategic role. Research on this topic is carried out in funded as well as in industrial projects. Hollow or constructed camshafts, crankshaft and gear shafts are main products realized within the framework of these projects. In addition to lightweight construction, the implementation of net-shape technologies represents a further objective to minimize resources for realizing these powertrain components. The contribution will present selected research activities of the Fraunhofer Institute for Machine Tools and Forming Technologies in this field. Furthermore, it will illustrate achievable effects concerning the weight reduction and efficiency increase in car operation as well as in vehicle manufacturing.