A comparative cost analysis of conventional wrought steel and powder metallurgy (PM) gear manufacturing technologies
(2019)- Abstract
- The transportation industry landscape is going through a massive transformation due to trends such as autonomous and electrified vehicles. The electrification trend has already started to display its ample influence on the automotive industry. New modern power and drivetrains need to be designed and manufactured based on the raising automakers’ requirements e.g. higher performance, better noise vibration harshness (NVH) behaviour. Meanwhile, cost must be minimized in order to obtain or secure market competitiveness.
In the highly cost-competitive atmosphere of the manufacturing sector,
particularly within the automotive industry, which is the focus of this licentiate,
manufacturing firms uninterruptedly seek to develop, adopt... (More) - The transportation industry landscape is going through a massive transformation due to trends such as autonomous and electrified vehicles. The electrification trend has already started to display its ample influence on the automotive industry. New modern power and drivetrains need to be designed and manufactured based on the raising automakers’ requirements e.g. higher performance, better noise vibration harshness (NVH) behaviour. Meanwhile, cost must be minimized in order to obtain or secure market competitiveness.
In the highly cost-competitive atmosphere of the manufacturing sector,
particularly within the automotive industry, which is the focus of this licentiate,
manufacturing firms uninterruptedly seek to develop, adopt and utilise cost models and methods in order to evaluate e.g. their existing production systems or planning new investment for adoption and deployment of new technologies.
The industrial case studies, investigated in this licentiate, have gear
manufacturing as the focus. The gear and transmission component manufacturing
industry is an important sector as it provides one of the basic mechanical parts to
industrial segments where motion and power transfer are needed. Two gear
manufacturing techniques namely conventional wrought steel and powder
metallurgy (PM) are compared from a cost perspective. Given the required
performance and quality for automotive transmission application, the gear
manufacturing processing routes and their production steps and cost drivers are
analysed and compared through the utilisation of the selected cost model, called
performance part costing (PPC).
The industrial applicability of PPC model is compared with the commonly used
standard costing, its use and its modified variations among practitioners through the case studies. The pros and cons of each approach are discussed. Given the assumptions made and reported in this licentiate for two different scenarios, the gear manufacturing cost of the analysed PM processing route were 12% to 38% cheaper compared to the conventional wrought steel processing route. However, the acquisition cost for the analysed PM processing route were almost three times higher than that of the conventional wrought steel gear. (Less)
Please use this url to cite or link to this publication:
https://lup.lub.lu.se/record/8783e1f1-01e3-4e74-90c1-9de73bfdc1a2
- author
- Kianian, Babak LU
- supervisor
-
- Carin Andersson LU
- Pål Börjesson LU
- organization
- publishing date
- 2019
- type
- Thesis
- publication status
- published
- subject
- keywords
- Gear manufacturing, Manufacturing cost analysis, Powder metallurgy (PM), Press and sintering (P/S), Wrought steel conventional gear manufacturing, Decision support system (DSS), Sustainability, Sustainable production (SP), Automotive Industry
- pages
- 107 pages
- publisher
- Department of Mechanical Engineering, Lund University
- ISBN
- 978-91-7895-340-0
- 978-91-7895-341-7
- language
- English
- LU publication?
- yes
- id
- 8783e1f1-01e3-4e74-90c1-9de73bfdc1a2
- date added to LUP
- 2019-12-06 05:54:29
- date last changed
- 2020-01-24 10:22:22
@misc{8783e1f1-01e3-4e74-90c1-9de73bfdc1a2,
abstract = {{The transportation industry landscape is going through a massive transformation due to trends such as autonomous and electrified vehicles. The electrification trend has already started to display its ample influence on the automotive industry. New modern power and drivetrains need to be designed and manufactured based on the raising automakers’ requirements e.g. higher performance, better noise vibration harshness (NVH) behaviour. Meanwhile, cost must be minimized in order to obtain or secure market competitiveness.<br/>In the highly cost-competitive atmosphere of the manufacturing sector,<br/>particularly within the automotive industry, which is the focus of this licentiate,<br/>manufacturing firms uninterruptedly seek to develop, adopt and utilise cost models and methods in order to evaluate e.g. their existing production systems or planning new investment for adoption and deployment of new technologies.<br/>The industrial case studies, investigated in this licentiate, have gear<br/>manufacturing as the focus. The gear and transmission component manufacturing<br/>industry is an important sector as it provides one of the basic mechanical parts to<br/>industrial segments where motion and power transfer are needed. Two gear<br/>manufacturing techniques namely conventional wrought steel and powder<br/>metallurgy (PM) are compared from a cost perspective. Given the required<br/>performance and quality for automotive transmission application, the gear<br/>manufacturing processing routes and their production steps and cost drivers are<br/>analysed and compared through the utilisation of the selected cost model, called<br/>performance part costing (PPC).<br/>The industrial applicability of PPC model is compared with the commonly used<br/>standard costing, its use and its modified variations among practitioners through the case studies. The pros and cons of each approach are discussed. Given the assumptions made and reported in this licentiate for two different scenarios, the gear manufacturing cost of the analysed PM processing route were 12% to 38% cheaper compared to the conventional wrought steel processing route. However, the acquisition cost for the analysed PM processing route were almost three times higher than that of the conventional wrought steel gear.}},
author = {{Kianian, Babak}},
isbn = {{978-91-7895-340-0}},
keywords = {{Gear manufacturing; Manufacturing cost analysis; Powder metallurgy (PM); Press and sintering (P/S); Wrought steel conventional gear manufacturing; Decision support system (DSS); Sustainability; Sustainable production (SP); Automotive Industry}},
language = {{eng}},
note = {{Licentiate Thesis}},
publisher = {{Department of Mechanical Engineering, Lund University}},
title = {{A comparative cost analysis of conventional wrought steel and powder metallurgy (PM) gear manufacturing technologies}},
url = {{https://lup.lub.lu.se/search/files/72921260/Babak_Kianian_licentiate_thesis_without_the_papers_attached.pdf}},
year = {{2019}},
}