Projects

The research conducted within the research programmes and initiatives in product and production development continuously results in new projects and findings. The projects are run in collaboration between universities, institutes and companies with great importance for Swedish industry. Here you can read more about ongoing and completed projects.

Automotive components from renewable resources with good barrier properties and tailored biodegradability, for interior applications

2012-2013

FFI

Our hypothesis is that advanced, lightweight, multi-layer-structured composites with good barrier properties and tailored biodegradability can be produced by combining bio-based thermoplastic with special additives and pulp fiber mats. This material is free from fossil raw materials, sustainable, fire and impact-resistant and suitable for interior components in vehicles.

Compact and energy efficient transmissions – control and prediction of functional surface behavior

2016-2018

FFI

The overall objective of the project was to: • Develop simulation methodology for drive simulation of transmissions with given shape, surface topography and surface structure, - for more robust and better prediction of the efficiency and life of gear contacts in gearboxes. • Through experimental evaluation and characterization, support and verify the developed simulation technology • Through experimental evaluation and characterization, further verifying the potential of using the correct surface texture, e.g. honing, and right-handed gear in heavy-duty transmissions.

Dense-Arc joining of hybrid thermoplastic composite-metal structures (DENSARC)

2012-2013

FFI

The aim with the project is to test a new method to join thermoplastic composite to metal in a lap joint by using a focused TIG arc, as a heat source, to heat the metal side just enough so that the composite melts and join to the metal. The method gives single sided access, no need for additional filler material and makes invisible joints possible. The objective is to have a joining method that is robust, gives high productivity and high quality as well as cost advantages.

Emerging digital technologies and their applicability as picking support in materials handling

2017-2017

FFI, Material Handling

In material handling processes, such as kitting and sequencing, which are used in the automotive industry to supply the assembly with a wide and growing range of component variants, the picking information system is central design aspect. Given the developments in digitization, the purpose of this concept study is to evaluate the potential of digital technology to support materials handling work in production systems.

Enabling super quality electric steel through advanced use of data analytics in real time

2017-2018

The revolution of electrical vehicles has started and several of the major carmakers have declared that the goal will be met within the next 2-3 years. This cause increased needs for qualitative steels for electrification of vehicle pow er. Suppliers of electrical metals does not meet the needs for high quality input materials. The SuperSteel project will investigate how a project that combines know ledge capture and management, data management and advanced analytics from all actors in the supply chain can be implemented to realise the required product quality in a flexible production.

Flexible Models for Predictive Maintenance

2017-2018

Automation, Digital Twin, Maintenance

Maintenance in existing plants is becoming increasingly important, where predictive maintenance has become an emerging technology. The use of decision support tools contributes to environmentally and economically sustainable production. Within this project, different types of digital twins have been designed and evaluated. Specifically, new predictive model types have been tested in two different industrial case studies; a heat exchanger at SSAB and a profiled header at Svenska Fönster AB.

Geometry optimized adhesive joining for sustainable production

2013-2015

FFI

"Geometry Optimised adhesive joining for sustainable production” in Swedish (Geometri Optimerad LimFogning för hållbar produktion, "GOLF") is a project within the Swedish research program FFI for Sustainable production. It has as its mission to develop technology and methods to get the right amount of adhesive on the right place. The drivers behind this are the overall strive to decrease weight in vehicles and moving machines to minimize the amount of CO2 in the atmosphere.

New and flexible process for joining heat exchangers

2017-2018

Flexibillity, Soldering

Traditional soldering of heat exchanger plates is carried out batchwise by time-consuming heating in an oven with vacuum or protective gas atmosphere. The industry seeks a production flow, where each product is treated separately at different stations. By using ohmic heating directly on the heat exchanger package, short cycle times, low energy consumption, easy conversion, and high, measurable quality can be achieved.

Non-poisonous substitute for hard chrome in volume applications

2017-2018

Chrome Replacement

This project explores the possibility of replacing hard chrome coatings on steel in volume applications with the Swedish innovation, TiSurf, which is a hardened nitride surface on titanium with excellent chemical and mechanical resistance. The long-term objectives are a more sustainable and cost-effective production of environmentally friendly hybrid materials to replace cancerogenic chrome based hard coatings and to create new application opportunities and markets. Therefore, the objective of the project is to develop and evaluate possible processes for hardened nitride surface on titanium with respect to relevant material and mechanical properties, to investigate and verify its potential as a sustainable replacement material for hard chrome and in various applications, such as piston rods, axles and tubes.

PADOK – Study Visit to India 2016

2016-2016

2030, FFI

With globalization and other megatrends as demographic changes and climate change, more knowledge is needed regarding production in an international perspective. PADOK Study Visit in India 2016 have given an increased knowledge regarding how production is conducted in India, some of the challenges producing companies in that region is facing and how Swedish companies interested in investing in production in India could act to establish themselves in the region.

Positioning technology for the heavy manufacturing industry

2017-2018

Automation, Communication, Digitalization, Security, Working Enviroment

The project aims at radically improving the working environment and the employee security within the heavy manufacturing industries by using and adapting the latest technology for low and ultraprecise positioning and decision support systems. The target is to increase security and safety by adapting the decision-support and positioning system for the heavy manufacturing industries.

Sintered parts with high static loading capacity

2012-2013

FFI

The project has confirmed the hypothesis that tailoring of the tempering is a functioning means of making PM steel sustainable towards high static loading in potential automotive applications. The project has also developed further understanding about mechanisms that could be responsible for static loading sensitivity with respect to creep/relaxation at slightly elevated temperature. The results relate to sustainable manufacturing processes, the basis being that powder compaction and sintering is an energy efficient way with high raw materials utilization.

Streamlined Modeling and Decision Support for Fact-based Production Development (StreaMod)

2013-2017

FFI

The integration of data management systems, simulation software and optimization algorithms have been shown to increase throughput in existing production but also allow expanded use of virtual tools in the preparation phases. This in turn leads to shorter development times for new production systems and products. The project has also contributed to greater understanding and concrete improvements in the processes of collecting and assure the quality of production data. This in turn increases the quality in both simulations and direct data-driven analyzes.

Sustainable Manufacture of Future Engine Components

2012-2015

FFI

The project has addressed challenges in casting and realisation of new cast irons with improved properties and machinability, decision making regarding manufacturing strategies and machinability of materials. Silicon-alloyed compacted graphite iron (CGI) has been demonstrated av new alternative for future engine components. New simulation technique for assessing manufacturing strategies has been introduced. Generic know ledge has been developed w hen it concerns w ork material machinability w ith specific reference to combined materials in advanced components.

Sustainable Metal Powder Utilization in Powder Bed Fusion Additive Manufacturing

2017-2018

3D-Printing, Additive Manufacturing, Assembly, Powder Bed Fusion

This project intends to design and develop a new test methodology for evaluation of power flowability in powder bed fusion (PBF) systems. The test apparatus will simulate powder flow in PBF machines and can be used for optimizing the powder layering behavior for potential utilization of alternative powder qualities. Additionally, this equipment creates opportunities for both powder producers and AM part manufacturers to minimize powder waste and maximize material utilization.

Tailored Tool Surfaces for Robust and Sustainable Hot Stamping

2015-2018

2030, Resource-efficient production

Tooling constitutes a significant part in the economical investment of the hot stamping process. Significant benefits in production economy and environmental benefits can be attained by improving the tribological performance in hot forming operations of automotive components. The main idea of this project is to create tailored tool surfaces on dies made from cheaper and easier to manufacture tool steel for the hot stamping of ultra-high strength steels.

Total offerings in manufacturing industries in Sweden – a lift

2013-2016

Potential to increase sales is large in companies that manage to switch from supplying goods with strong price competition to develop and deliver total offerings with a higher perceived value for the customer. The project aims to contribute to more manufacturing SMEs in Sweden realizing this potential. The goal is to develop and pilot test a scalable model for coaching SME´s shift towards creating and delivering innovative and sustainable total offerings and thus enhanced competitiveness. The project will also develop a plan for further scaling up from 2017 onwards.

Variation Prediction and Source Identification for Zero-defect Machining Line

2016-2018

Identification

In multi-stage machining, errors or variations in machined part features propagate downstream from process to process through the entire machining line. The objective of the project is to enable achieving a zero defect production by predicting and controlling variation and their propagation in multi-stage machining. This demands capturing the relations between variations and their sources in a multi stage machining. The project activities will be based on three industrial cases at Scania, LEAX AB, and GKN. The cases are meant to ground the already proven state of the art concepts in variation modelling, data analytics, measurement, precision pallet system, and simulation in real industrial applications. The application area of the project result covers manufacturability analysis, tolerance analysis, process planning as well as quality assurance strategies. The results and the demonstrations will be of interest to SME and large companies having multi stage machining.

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