Cost effective transmission input shaft development

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Customer: Tier 1 supplier to the automotive industry

Market: Light duty on highway - Asia

BRACE execution: Powertrain domain cluster

Location: BRACE Offices and Customer site

The goal of the development is to make a cost effective design for a transmission input shaft. This input shaft has to fulfill lots of functions (bearing raceways, spline connections, etc.) and therefore manufacturing it out of one part was not very cost effective.

Different concepts were generated in cooperation with a team at the client containing development, project, manufacturing and process engineers. A concept was chosen in which the input shaft is manufactured out of 2 parts, a turned part and a stamped part, which almost halved the price of this component.

The detailed design consisted of:

  • Technical drawing
  • Welding specification
  • Test procedure for the weld
  • FEA
  • Tolerance study
  • Design FMEA