JPMA Award Winners 2014

The winners of the Japan Powder Metallurgy Association’s (JPMA) 2014 Powder Metallurgy Awards reflect an industry continuing to develop and expand the range of applications suited to PM technology. The awards recognise innovations in new materials, manufacturing processes and component design. Evident again in this year’s awards are the increasing number of applications for PM in hybrid and electric vehicles, as well as opportunities for replacing traditional production routes with more environmentally friendly PM options.

 

Development prize: New design

 

Synchroniser hub for a Dual Clutch Transmission

JPMA Award Winners 2014

A low speed synchroniser hub used in a seven-speed DCT (Dual Clutch Transmission) for a Hybrid Electric Vehicle (Courtesy JPMA)

 

Sumitomo Electric Industries Ltd received an award for a low speed synchroniser hub used in a seven speed Dual Clutch Transmission (DCT) for a hybrid electric vehicle. DCTs offer a number of features including computer controlled automatic shifting and efficiency as high as that of manual transmissions, due to the absence of a torque converter helping to reduce fuel consumption.

However, weight and cost reduction are also required for DCTs because of their complex design and large number of components. To address this a high strength synchroniser hub with a helical gear form and thin wall was developed (Fig. 1). The compaction punches were divided in order to adjust the density balance of the ridges on the flange section and to rotate the punch used to form the helical gear section. Material and surface condition of the compaction tooling were optimised to prevent sticking between the bottom of the punch and the die. An exacting 19 μm tolerance of the inner diameter was achieved by using a special machining chuck to reduce deformation.

 

Air compressor component with thin-walled part for electric vehicle

Air compressor component with thin-walled part for electric vehicle (Courtesy JPMA)

 

Diamet Corporation received an award for the development of the oldham ring of a scroll compressor used in the air conditioner of an electric vehicle.

In order to extend the mileage range of electric vehicles there is a high demand for smaller, lighter components. A 50% reduction in weight and flange thickness was required in comparison with a conventionally produced oldham ring. In addition, cost reduction was also requested by the customer.

The oldham ring was developed to be produced without machining in order to reduce cost. To achieve better flatness of the thin flange, filling conditions, sintering jigs and sizing conditions were optimised. To avoid cracks and deformation of the green compact with a thin flange during transfer, magnetic handling was utilised.

As a result, the mass production of the oldham ring was achieved and both the weight and flange thickness were successfully reduced by a half.

 

Sprocket with crank sensor for a diesel engine

A sprocket with crank sensor for use in a diesel engine (Courtesy JPMA)

 

Diamet Corporation also received an award for the development of a sprocket with crank sensor for use in a diesel engine. The assembly of a sintered sprocket and a sensor made from sheet metal was replaced with the new product for the purposes of cost reduction and downsizing. Because of the integration of the components the margin for assembly was eliminated.

The geometry of the crack sensor was modified to reduce size by utilising the near net shape method of sintering. In order to avoid breakage of the small teeth during compaction, both a lubricant addition and a tooling coating were used. The high precision of the inner diameter was achieved without grinding by optimising the powder filling and sizing process steps.

As a result, the mass production of the sprocket with crank sensor for diesel engines was achieved, with the forged crank sensor being successfully replaced.

In the latest issue of PM Review…

Download PDF

Extensive Powder Metallurgy industry news coverage, and the following exclusive deep-dive articles and reports:

  • Powder Metallurgy’s challenge: How does automotive’s reliance on model-based decision making impact our industry?
  • How to make metal powders. Part 4: Centrifugal and other special atomisation methods
  • Precision and energy efficiency in PM press technology: Insights from Ceramitec 2022
  • Historic traditions and new innovations: refractory metals and hard materials at the 20th Plansee Seminar
  • Tailoring a speciality alloy for Additive Manufacturing: From powder production to parameter optimisation
  • Understanding the compaction and sintering effects of four commonly used lubricants in Powder Metallurgy

The latest news from the world of metal powders, delivered to your inbox

Don't miss any new issue of PM Review, and get the latest industry news. Sign up to our weekly newsletter.

Sign up

From the industry…

Discover our magazine archive…

The free-to-access PM Review magazine archive offers unparalleled insight into the world of Powder Metallurgy from a commercial and technological perspective through:

  • Reports on visits to leading PM part manufacturers, metal powder manufacturers and industry suppliers
  • Articles on technology and application trends
  • Information on materials developments
  • Reviews of key technical presentations from the international conference circuit
  • International industry news

All past issues are available to download as free PDFs or view in your browser.

 

Browse the archive

 

Looking for PM production equipment, metal powders, R&D support and more?

Discover suppliers of these and more in our
advertisers’ index and buyer’s guide, available in the back of PM Review magazine.

  • Powders & materials
  • Powder process, classification & analysis
  • PM products
  • Atomisers & powder production technology
  • Compaction presses, tooling & ancillaries
  • Sintering equipment & ancillaries
  • Post-processing
  • Consulting & toll sintering
Download PDF
Copy link