2009

visiting‑address: university campus, porsön, luleå

postal address: SE-971 87 luleå, sweden

telephone: +46(0)920-49 10 00. fax: +46(0)920-996 92

website: www.ltu.se www.ltu.se/tfm/cad

FINAL-YEAR COURSE IN

MECHANICAL ENGINEERING DESIGN

IN THE MECHANICAL ENGINEERING

MSc PROGRAMME AT

LULEÅ UNIVERSIT Y OF TECHNOLOGY

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3

Sirius 2008/09 is a collaborative programme involving Luleå University of Technology

together with the Faste Laboratory partners Volvo Aero, Hägglunds Drives AB,

AB Sandvik Coromant, Gestamp Hardtech, Volvo Construction Equipment and

several other industrial and academic partners.

Sirius prepares students for work in product development. The product development

projects of this course are firmly based on close collaboration with industrial manu-

facturers or on real product development needs identified in other ways. Work is

conducted in project groups with the support and guidance of academic and

industry advisors. Collaboration benefits both students and industry partners by

giving students an opportunity to apply their knowledge when developing optimal

solutions to real design problems with a limited time frame and budget. A unique

insight into present and future working methods and cooperation in product devel-

opment is gained.

Manufacturing companies gain access to innovative product development

performed by well-educated engineers who are unbiased by traditional modes of

thinking and problem solving.

Luleå University of Technology and industry partners in collaboration

Sirius is a final-year course for students in

the Mechanical Engineering MSc degree

programme at Luleå University of Techno-

logy. Sirius is also open to final-year

students from other MSc engineering pro-

grammes at the university, thereby ensuring

a broad base of knowledge for the course’s

project groups. During most of the 22.5-

credit course, product development pro-

jects are conducted in close national and

international collaboration with compa-

nies and universities. The aim of Sirius

is for students to acquire, apply and

integrate knowledge considered essen-

tial for product developers in modern

manufacturing industries.

Students gain knowledge in project

management, production of creative con-

cepts, mechanical engineering design and

computer-aided engineering, as well as

command of all stages in the integrated

product development chain, from needs

analysis to the finished product. Under rea-

listic industrial conditions, they carry out

product development in teams, in colla-

boration with manufacturing companies

based on real needs. Experience from

Sirius prepares the participants well for

teamwork with colleagues from other

disciplines. Students also take courses

in product development methods, com-

puter-aided modelling and analysis, and

project management, courses which

support their development projects.

Sirius students engage in a valuable ex-

change of knowledge and ideas with

graduate students and staff from

the Faste Laboratory and other depart-

ments of Luleå University of Technology.

Not only do Sirius students have solid

theoretical knowledge, they also have the

benefit of valuable experience from work

in an integrated environment where me-

thods and ideas from the research at the

division of Computer Aided Design have

been applied.

Creative product development

For more information

about previous Sirius

projects, please visit

www.ltu.se/tfm/cad/

sirius.

2

NeedfindingA user focus has come to dominate compa-

ny innovation strategies in the past decade.

However, in practice, involving users in pro-

duct development is not as straightforward

as it sounds. People cannot always be pre-

cise about what their needs are; they might

just perceive a situation where satisfactory

solutions are lacking. In such situations, it

is naturally more difficult to identify these

needs. Needs obviously play an important

role in innovative or radical product design,

since the starting position includes no exis-

ting solution.

Thirty years ago, Robert McKim, the

head of Stanford University’s product design

programme, understood that engineers had

to be involved during the earliest stages

of product development to understand

needs. He developed an approach, named

Needfinding. Needfinding implies the inter-

play between needs and recognition.

Observations, interviews and creative

methods are used to identify, analyse, cate-

gorise and communicate needs to drive pro-

duct development in Sirius student projects.

The main principles of Needfinding are to first

be close to the users and then look for needs,

not solutions. This keeps the early phases

of product development open to unexpec-

ted insights and supports the generation of

numerous concept ideas. In turn, this broa-

dens the design space and the opportunities

for innovative products. This contradicts a

problem-solving approach of product deve-

lopment, where reducing the number of

concepts as early as possible is important.

Needfinding is part of the Sirius guideline that

provides students with capabilities beyond

classical engineering design education. The

insights into needs provide a solid ground

for the activities in concept generation, con-

cept evaluation, detail design and product

launch, which are also main parts in the Sirius

guideline.

Concept generationAs Needfinding activities unfold, students

gradually perceive insights into people’s

needs and concept ideas. To work the ideas

into comprehensible concepts, the use of

creative methods is emphasised. The use

of creative methods spurs a free mind and

openness to new ideas, since judgmental

attitudes are not allowed and all ideas are

good ideas. The concept generation phase

has a focus on quantity, i.e. as many ideas

as possible. Examples of creative methods

are brainstorming, method 653, brainwriting,

bodystorming, and de Bono’s six thinking

hats. The use of creative tools, e.g. method

cards and thinkpak, support thinking outside

the box and using all senses to be creative in

the concept generation activities.

Concept generation is, in particular,

highly iterative. The generation activities

occur on different levels throughout the entire

product development process as the product

matures.

of Quality and Pugh’s matrix, are used. Small

models or prototypes may be used to test if

a concept should be further developed. The

idea here is to keep the prototype as simple

as possible, since only particular concepts

should be tested. Concept generation and

concept evaluation are closely related pha-

ses and are used to narrow down and open

up the design space. The results from the

Needfinding activities, i.e. the needs in focus,

are used in the evaluation activities to, for

instance, judge a user-perceived value of the

concept.

Detail designAfter iteratively framing and reframing the

concepts in the evaluation phase, a few con-

cepts are chosen for further development.

Detail design is a stage where the concepts

become more explicit in terms of solutions

and functionality. Still, the chosen concepts

are at various stages of completion. There-

fore, a range of approaches is used. Com-

puter-aided engineering and design tools

such as multi-body dynamic analysis and

finite element analysis are used, along with

engineering design method and methodolo-

gies, e.g. case-based reasoning, knowled-

ge-based engineering, and industrial design

approaches. The Sirius course encompas-

ses a diversity of products to be developed;

thus, the choice of approach or approaches

depends on the focus in the student project.

Concept evaluationNumerous concepts are created during the

concept generation phase; approximately

100-150 concepts are not unusual. This pleth-

ora of concepts has to be narrowed down into

a manageable size during a phase referred to

as concept evaluation. Concept evaluation

can be seen as activities that highlight some

desired qualities in each concept and can be

seen as a stage in the design process during

which the design space is narrowed down.

The aim is to extract a few concepts that best

meet the needs in focus and are feasible to be

further developed into a product. However,

to build upon seemingly crazy ideas from the

concept generation, the concepts have to be

described more concretely.

A first round of evaluations can be per-

formed, for example, by using creative tools

where the focus is on judging the value of the

idea. During the later stages, measurable cri-

teria and matrix-based methods, e.g. House

Product launchCompleting the whole product development

process from identifying and understanding

needs to product launch is a basic require-

ment of the Sirius guideline. The Sirius stu-

dent projects are performed under realistic

conditions, in most cases, in collaboration

with companies. Therefore, the expectations

on the products are high. Several produc-

ts developed within the Sirius programme

are further developed and implemented

by the companies. Not only is it important

to design a competitive product in terms of

design, ergonomics, aesthetics, etc., but it

is also important that the students have the

opportunity to practice their skills in selling

and explaining their ideas. Hence, ideas

and concepts are continuously presented

to industry partners, teaching staff or both

throughout the programme. The programme

concludes with a public event during which

student projects and products are presen-

ted. This is a day when many students are

pleased to show what they have achieved,

and when the Sirius personnel are full of pride

for their students.

54

6 7

Design Space Exploration

Roadmap

Concept Design & Prototyping

Gestamp HardTechStudents were given the task to develop a

crash test cart for bumper testing. The test

cart had to be able to mimic the dynamic

behaviour of both small and large passenger

cars. Along with the final design a program

was delivered instructing the test engineer

how to set up the cart.

Hägglunds DrivesStudents have together with Hägglunds

Drives AB developed an innovative compact

hydraulic drive system suitable to power

conveyors or similar products. The system

is compact and effective and designed to be

an especially competitive drive solution for

operating at high torque and low power range.

A full-scale functional prototype was built

and evaluated. This prototype will be further

tested in the laboratory at Hägglunds Drives

AB in Mellansel during 2009 and 2010.

LTU Eco Marathon The Shell Eco Marathon is an educational

project that integrates the sustainable deve-

lopment values with driving a vehicle using

the least amount of energy.

Over the years, the fuel economy record

has been rapidly improved. Last year LTU

competed for the first time and won its class.

The vehicle, named Baldos, ran 299 km

using only one litre of gasoline, breaking the

world record in carbon dioxide emissions by

6 g/km.

In early May this year, LTU will compete in the

25th annual edition of the European Shell Eco

Marathon with a new version of Baldos. We

hope to perform even better than last year.

Sandvik CoromantTogether with AB Sandvik Coromant the stu-

dents have developed an integrated adjusting

device for indexable drilling tools, to enable

an adjustment of the peripheral insert. This

will make it possible to achieve a closer hole

tolerance.

Volvo Aero The Turbine Rear Frame (TRF) is a load carry-

ing structure located in the aft of a jet engine.

The task was to develop a new TRF design

with improved aerodynamic abilities while

considering the high operational tempera-

ture and maintaining a low weight. Together

with Volvo Aero Corporation the students

developed and evaluated a new design that

shows good robustness and good potential

for further development..

Volvo Construction EquipmentA fully functional prototype and a production-

ready model of the drop box were develo-

ped.

Success in the Shell Eco Marathon

The students from the Sirius programme in 2008 participated for

the first time in the Shell Eco Marathon. The aim of the compe-

tition is to encourage and promote innovation and ideas in the

area of climate-friendly vehicles and sustainable transportation.

The future demand for energy-efficient vehicles was a moti-

vational factor for the team. The students clearly understood,

adopted and improved the technique needed for ultra-high fuel

efficient vehicles. The hybrid powered urban vehicle named

BALDOS succeeded in the competition and was awarded seve-

ral prizes.

Baldos showed an extremely low fuel consumption of 299

Km/l, which resulted in a first place in the Michelin Grand Prize

Combustion Engine class.

A technical solution whereby the engine exhaust gas was

recirculated into the combustion engine for improved efficiency

was awarded with the Bosch Technical Innovation prize.

The technical solutions and the overall performance of the

car resulted in a minimal environmental impact during usage.

The resulting total life-cycle carbon dioxide emissions were 6.15

g CO2/Km, which includes all emissions from production, trans-

portation and final use. For this achievement, the team were

honoured with the Climate Friendly Prize.

Compact Electro-Hydraulic Variable-Speed Drive System

Hägglunds Drives has participated in SIRIUS every year since

2003/2004.

To be more competitive on the market we have to reduce

weight, number of components and at the same time improve

efficiency and reliability for our hydraulic drive systems. A good

example is a project that started up as a conceptual study in

the Sirius project 2007/2008. The students delivered a mock-

up in scale 1:2 that was presented for Hägglunds Drives in May

2008.

A decision was taken to pursue the concept and develop

a full-scale prototype for testing in our laboratory. The Sirius

project 2008/2009 has already proven that it is realistic to build

a more competitive drive system from components that can be

found on the market today.

It was also important to reduce oil volume and use a more

sophisticated oil that can withstand higher oil temperatures to

improve the cooling capacity. Close collaboration between the

divisions of Computer Aided Design and Machine Elements has

been an important factor for knowledge sharing and testing of

principles by using tribo-testing in the Tribolab at LTU.

Further testing in our laboratory in Mellansel is planned

as part of an MSc thesis project that will begin in September

2009.

Integrated Outlet Guide Vane in Aluminum

Volvo Aero Corporation (VAC) became a partner in the Sirius

Creative Product Development programme in 2001/2002 and

has participated every year since then.

In 2007/2008 the VAC project consisted of designing an

integrated outlet guide vane (OGV) in aluminum for the next-

generation single-aisle aircraft. The OGV is part of the inter-

mediate case (IMC) located right behind the fan in turbo fan

jet engines. It is traditionally made of titanium castings, which

makes it strong but very expensive. The IMC has two functions;

load transfer from the core structure of the engine, which is

conventionally done by means of struts, and redirecting the

air flow through the bypass duct via guide vanes. Choosing

aluminum over titanium and integrating the load carrying and

aerodynamic functions enables a lighter, cheaper design. The

goal of the project was to find a design and manufacturing tech-

nique that would decrease the design weight and radically bring

down the product cost without jeopardizing the integrity of the

IMC. An extensive study in aluminum alloys and manufacturing

techniques was performed, design proposals were developed

and structural analyses carried out. For the first time ever in a

VAC Sirius project three full-scale prototypes were manufactu-

red to verify the computer-aided structural analyses.

A manufacturing technique that offers vast cost advantages

over casting titanium was found. The prototypes demonstrated

coherence between simulated and experimental results. As the

manufacturing technique in question continues to develop at a

fast rate, it is likely to be used in production of future OGVs.

Sirius success storiesSirius 2008/09 Product development projects

8

Background

Gestamp HardTech, with headquarters in

Luleå, Sweden, is the world-leading company

for the press hardening technique. Gestamp

HardTech specializes in developing and ma-

nufacturing high-strength safety components

for the automotive industry. The demand for

such components increases as costs for fuel

and raw materials rise.

The growing number of Suburban Utility

Vehicles (SUVs) has lead to higher insurance

claims related to low-speed impacts. Most

of the damage is a result of the mismatch

between bumper heights of regular cars and

SUVs, which causes under and over ride. The

result is that other more expensive parts have

to absorb the impact.

To mitigate the situation and lower repair

costs, the Insurance Institute for Highway

Safety (IIHS) instituted a new low-speed

impact test that tries to mimic the bumper

geometry of an SUV. This causes problems,

because today’s testing equipment cannot

verify bumper functionality during the IIHS

test, thus there is a need for new equipment.

Assignment

The specific task was to develop a new crash

test cart with the possibility to adjust mechani-

cal parameters in order to reach good cor-

relation with most vehicles on the market.

Parameters that were identified as important

are position for centre of gravity, moments of

inertia, suspension spring constant, suspen-

Product Development Process

The team has worked according to the “Sirius

Masterplan of Creative Product Develop-

ment”. In the early stages the group made

many observations and investigated on the

customer’s needs and demands of the final

product. With this information the team could

determine the product characteristics. These

requirements served as a basis for the brain-

storming workshops where new concepts

were generated. The concepts were then

evaluated for their suitability to the product

characteristics. The process of brainstorming

and evaluation was iterated until satisfying

results were achieved. To test the concepts,

Computer Aided Design and Finite Element

Analysis were used. The dynamic behaviour

of the cart was also tested with dynamic simu-

lations in ADAMS.

Gestamp HardTech strives to reduce the weight and increase

the strength of safety products for passenger vehicles. Product

development work is done in close cooperation with the custom-

ers. The company continually collaborates with university stu-

dents to exchange knowledge and experience in these types of

projects.

Gestamp HardTechLighter more cost-effective solutions

Gestamp HardTech invented and developed the presshardening

technology. With this technology Gestamp HardTech can offer

the OEM’s improved solutions in order to meet challenges for

the future in the field of: environmental topics e.g. reduced fuel

consumption, crash protection and cost effectiveness. Our goal

is to remain as the global leader in the field of the pressharden-

ing technology.

Results

The end results were manufacturing drawings

for a fully functional adjustable test cart and

corresponding list of materials with contact

information to potential suppliers. Along with

the drawings, a program instructs the test

engineers as to how they should go about

configuring the test cart to enable the desired

dynamic behaviour.

9

Top row, from left: Petter Ulfberg, Pär Mikaelsson, Filip Berglund

Bottom row, from left: Johan Nilsson, Andreas Lindberg,

Jonas Pavasson Hatta, Mikael Nybacka (coach)

Testing protoype of the air spring.

One of the investigated suspension types.Adjustable air spring used in the test cart.

Early concept of the complete crash test cart.

sion damping constant, track-width and

wheelbase. Additionally, the weight should

be adjustable in the range of 800-3000 kg to

represent all sizes of vehicles. These param-

eters should also be quick and easy to set

and modify. There was also a requirement to

integrate results from the DYNSYS research

project, which aims to model how much iner-

tial energy is transferred to the bumper during

a-low speed collision. At the end of

the project the team should have

delivered manufacturing drawings

for a fully functional crash test cart.

1110

Background

Hägglunds Drives AB is one of the worlds lead-

ing companies in hydraulic drive solutions. The

head office is located in Mellansel, Sweden,

with production and sales offices all around

the world. The company’s product range is

exceptionally competitive at high torque and

variable speeds below 100 rpm. For variable

speeds below 5 rpm the competition is tough-

er from alternative solutions such as electro-

mechanical drives. To face this challenge,

Hägglunds Drives AB in the last year’s Sirius

project performed a concept study on a new

compact hydraulic drive system designed for

this particular market segment.

Assignment

This years Sirius project continues with the

goal to design and manufacture a full-scale

functional prototype that was to be tested and

evaluated at Luleå University of Technology.

Desired features for the new drive system

included efficiency, compactness and a robust

and attractive design that suits the characteris-

tic Hägglunds Drives appearance of high relia-

bility. The design should also minimize the need

for external cooling and piping while simultane-

ously keeping system noise to a minimum. In

addition to the technical system performance

evaluation, the assignment also included cost

and weight evaluations.

Design for manufacture

Throughout the development process the

project group has worked according to the

“Sirius Masterplan”, from idea generation to

finished prototype. Because a full-scale work-

ing prototype was to be built much of the work

was carried out in the mid to late part of the

product development process. The develop-

ment team went through literature studies,

design space explorations and concept design

and finally focused on the detail design phase.

In this stage the concept was transformed into

a product and all the work had to be performed

with the system's manufacturability in mind.

To ensure that the system worked in theory

before being built it was essential that through-

out, accurate dimensioning calculations were

performed. Also, in order to suggest a suitable

oil for the system, a tribology study of oils oper-

ating at elevated temperature was conducted,

after which an appropriate oil was chosen.

Hägglunds Drives AB continuously strives to improve their

Hydraulic drive systems to make them even more efficient.

To be more competitive in the compact, high-torque, low-

power market segment the company worked together with

students from Luleå University of Technology to design an

innovative, integrated electro-hydraulic drive system that

complements their product range.

Results

After thorough concept evaluation of the main

system as well as of the sub systems the team

selected a concept called FCDS; Frequency

Control led Drive System. Compared to

Hägglunds Drives AB’s current compara-

ble drive system the weight was reduced by

approximately 25% while the theoretical total

efficiency was increased to approximately

84-86%. Newly developed features which

make the improvements possible Include a

new control system and a new cooling system

that functions without an external oil tank. This

concept was built as a fully functional proto-

type which was tested and evaluated at Luleå

University of Technology.

The system will also be further tested in

the test laboratory at Hägglunds Drives AB in

Mellansel during 2009 and 2010.

Hägglunds Drives ABMore than an ordinary drive supplier

DUSTIER, DIRTIER, HARSHER, HEAVIER.

The worse it is, the better equipped we are. After

more than four decades of supplying drive systems for

heavy industrial applications, Hägglunds is accustomed to

difficult demands. We provide what you need to get through

the toughest jobs done right – no matter how harsh the environ-

ment or how specialized the tasks

PERFORMANCE, FLEXIBILITY, SECURITY.

Hägglunds unique hydraulic systems – combined with our wealth of

experience – provide advantages no other drive supplier can match.

With Hägglunds drives on your equipment, you gain:

Maximum torque from zero speed

High performance regardless of condition

Precise control of infinitely variable speed

Standardized modules for design freedom

Smaller, lighter, more efficient installations

Superior protection of equipment and processes

HERE, THERE, EVERYWHERE.

A global leader in industrial drive solutions, Hägglunds has

offices in nearly twenty countries and distribution partners in

many more. We are where you are – with short lead times

and fast, comprehensive service that meets you needs.

OUR DRIVE IS YOUR PERFORMANCE.

Torque arm drawing

From left: Carl-Emil Bengtsson, Joakim Winsa, Jimmy Björnström, Jonas Pelli, Björn Backe,

Pär Marklund (coach)

Parker F12

hydraulic

pump

Jonas Pell i and Jimmy Björnström discusses

details in the system layout.

Full-scale functional prototype of

the concept FCDS – Frequency

Controlled Drive System

Hägglunds Drives CB280 hydraulic motor

Detail of Pall UR219 f i ltration unit

12 13

ing to Svensk Bilprovning (the Swedish Motor

Vehicle Inspection Company).

Organization

The team was divided into groups with different

areas of responsibility and expertise. The three

main groups were; chassis, body & ergonomics

and drive-train. Students from different depart-

ments of the university have been involved in

the project to ensure that all the needed com-

petencies were available early in the develop-

ment process.

Since no company supported the project

financially from the start, an important task has

been to recruit suppliers of parts and materials

as well as getting companies to invest in the

project as sponsors.

Results

The vehicle that has been developed is based

around a self-sustaining chassis made out of

carbon fibre and divynicell. A clever combi-

Baldos is the name of a car that is being developed

and manufactured by students at Luleå University of

Technology, LTU. Students at LTU have once again

accepted the challenge to build a vehicle that is as fuel

efficient as possible, as an entry for Shell Eco Marathon

2009. The team will compete in the 25th annual edition of

Shell Eco-marathon. This year’s race takes place at the

EuroSpeedway in Lausitz, Germany.

nation of twill (bi-directional carbon fibre) and

single-directional carbon fibre has resulted in

a chassis that is almost 50% lighter than last

year’s but still more rigid and robust.

The body has been designed with acces-

sibility and robustness in mind. The accessi-

bility has been improved by making it easier

to access the engine compartment and other

areas of the car that might need adjustments

during the competition. The body has also

been given a new access the driver’s com-

partment. The overall impression of the body

Background

Last year, a team from LTU competed for the

first time and placed first in its class. They also

came home with several special prices, includ-

ing the BOSCH technical innovation award.

They competed in the “Urban Concept Group”,

where the vehicles are designed to look as

much as real cars as possible. There are also

rules regarding outer measurements and ergo-

nomics aspects, etc.

Assignment

The goal was to create a vehicle to participate in

the race in early May. Like last year, we were set

to compete in the “Urban Concept Group”. The

key objectives were to make this year’s vehicle

lighter, more robust and also more ergonomi-

cally adapted. Of course, the main goal was

to outperform last year’s winner – ourselves.

As a bonus assignment, one goal was also to

design and manufacture the vehicle so that

it could be registered as street legal accord-

the energy stored in the super capacitor to run

the vehicle.

The vehicle features an on-board network

that controls the combustion engine, the elec-

trical motor, lights, driver’s interface, etc.

All this has resulted in a vehicle that looks

better, feels more robust and is more light-

weight, hopefully will perform even better in the

competition than last year’s.

The team would like to thank all partners

and sponsors that have provided money, parts,

knowledge and time. The project would not

have been possible without you.

More information about the project is avail-

able at www.baldos.se.

From left: Stefan Inglén, Johannes Carlsson,

Henrik Andersson, Per Nilsson, Jens Carlevi (coach),

Fredrik Löfgren

Sponsors 2009

SCANMOULD

CENTEK

KVASER

APC COMPOSIT

LULEÅ KOMMUN

ATMEL

TOOLTECH

SKF

TRIBOLAB

UDDEHOLM

BLUE CHEM

VAC

DIAB

LULEBO

MAGURA

STICKIT

SVENSKA TANSO

EMBEDDED ARTISTS

ELFA

HELLA

NOVIA INDUSTRI

MFT

AXI

EMAG

LESJÖFORS

MELMAC

DALHEMS

STYLINGWEBBEN

has been improved by adding details that

make it look more like a real production car.

An example of the high detail level and finish is

the head- and rear lights. These are integrated

with the body to create a more

sophisticated look.

The interior has been designed

to make the vehicle look and

feel as much like a real car as

possible. All the information

needed by the driver is presented on LCD-

screens placed in the dashboard. The interior

also features a padded driver’s seat that is inte-

grated with the combined roll-bar/firewall. This

makes the seat more than 80% lighter com-

pared to last year.

The drive-train is a serial hybrid with a

highly efficient, four-stroke 25 cc combus-

tion engine that runs on 100% ethanol, mak-

ing it possible to increase the compression.

The combustion engine drives a three-phase

generator that charges a super capacitor that

stores the energy. An electric motor then uses

1514 15

AB Sandvik CoromantAB Sandvik Coromant is part of the Sandvik AB global

industry group, world-leading within each of the business

areas Tooling, Mining and Construction and Materials

Technology. AB Sandvik Coromant belongs to the Tooling

business area and holds a world-leading position con-

tinuously striving for improvement within development

and manufacturing of cutting tools. With headquarters in

Sandviken, Sweden, the company is represented in more

than 130 countries word-wide. AB Sandvik Cormant has

long been synonymous with innovation and helping cus-

tomers increase productivity and profitability.

position, continuously working to improve

development and manufacturing of cutting

tools.

Assignment

The project has a focus on drilling tools and

the task involves developing an integrated

adjusting device for the peripheral insert on

an indexable drill. This device will make it

possible to get a closer hole-tolerance with

an indexable drill, which today is seen as a

roughing tool. The adjusting device should

assure rigid, precise and strong fastening but

still permit an easy change of drill diameter.

This is a challenge, since the cutting forces on

the cutting edge of such a tool are very high.

Design Process

The project was carried out according to the

Sirius Masterplan. The first step was to gather

information about customer needs and com-

peting solutions. With the gained knowledge

as a base the specification of requirements

was set. The next step was to generate ideas

and concepts that could satisfy set require-

ments. Through continuous brainstorming

sessions and workshops the ideas were

developed and improved into a number of

concepts. The final concepts were evaluated

through Pugh-matrices and FE-simulations.

Result

The strongest concept was further developed

through detailed design. The main benefits of

this concept are that it is feasible to implement

on small drill dimensions and has a good gear

ratio. After thorough calculations and analysis

a full-scale, fully functional prototype was

made and then successfully tested at Sandvik

Coromant.

Together with AB Sandvik Coromant the students have

developed an integrated adjusting device for indexable

drilling tools, to enable an adjustment of the peripheral

insert. This will make it possible to achieve a closer hole

tolerance.

Introduction

AB Sandvik Coromant strives to continuously

improve and develop its tools in order to pro-

vide customers with the best products on the

market. In the 2009 Sirius project the students

have designed an adjusting device for index-

able drilling tools, resulting in more versatile

tools.

Background

Manufacturing companies all over the world

face the same problem – the widening gap

between what the market is willing to pay and

the cost of production. Bridging this gap is

the only way to competitive, and this is how

Sandvik Coromant helps its customers.

AB Sandvik Coromant holds a world-leading

Top row, from left: Emma Rydh, Mojgan Mohseni, Lu Juan Juan, Rebecca Andersson,

Anna Söderlind. Bottom row, from left: Tomas Furucrona, Per Mattson, Jens Hardell (coach),

Peter Åström (coach), Magnus Persson

CoroDrill® 880

Juan Juan Lu looking at

a 3D printout of the final

concept.

CAD model of CoroDrill® 880

17

The global trend of transportation has increased

ever since the first civil aircraft were introduced.

Today, new environmental regulations and demands

combined with an aging and nearly obsolete fleet of air-

craft puts extra focus on the world’s aviation industry.

Volvo Aero Corporation (VAC) is developing and manu-

facturing new and complex structures for today's and

tomorrow's aircraft engines. One of these structures is

the Turbine Rear Frame (TRF).

The challenge was to present a concept

solution well adapted for the requirements

and flexible enough to adjust for tomorrow’s

requirements and new engine types.

Method

Early on, different brainstorming techniques

were used to generate a lot of different con-

ceptual ideas. Together with Volvo Aero these

ideas was narrowed down and enveloped

to a few concepts for further investigation.

To ensure that the requirements for these

concepts could be met, digital mock-ups of

Volvo Aero develops and produces components for commer-

cial aero, military aero and rocket engines with high technol-

ogy content, in cooperation with the world's leading aero

companies. Service and maintenance is an important part of

our operation. Volvo Aero offers an extensive range of service,

including maintenance, repair and overhaul of aero engines

and industrial gas turbines, sales of spare parts for aero

engines and aircraft as well as sales and leasing of complete

engines and aircraft.

Volvo Aero

pollution by 50 percent.

One way to realise the ACARE vision

is to redesign the aircraft and the engines. As

a consequence, the TRF needs to be made

lighter while increasing the aerodynamics and

without affecting the robustness of the prod-

uct.

Assignment

The aim of this project has been to design a new

conceptual TRF with separated functionality.

The final design needed to be well adap-

ted for large-scale manufacturing and in

line with the project constrains, as a cost,

aspect,material limitations due to strength,

thermal resistivity and vibrations.

Background

The environmental demands on the aviation

industry are higher than ever.

These demands affect the entire industry;

from in-air management to manufacturers and

subcontractors.

Experts say emission levels are falling by

an average of two percent every year as older

aircraft are replaced by more fuel-efficient

ones. The Advisory Council for Aerospace

Research in Europe has set the industry three

main targets for 2020.

The ACARE aims to cut the CO2 emissions

per passenger kilometre by 50 percent based

on the average level in the year 2000. The goal

also includes reduction of oxides of nitrogen

(NOx) by 80 percent and to reduce noise

the concepts were created using CAD and

Finite Element Analysis preformed to evaluate

the mechanical properties.

An important part of the project was to

manufacture a prototype that also proved to be

important for the evaluation of the manufactur-

ing aspects of the project.

Project progress was reported on a regular

basis to Volvo Aero, throughout ordinary phone

meetings but also by using and testing Volvo

Aero’s new software for distributed collabora-

tive engineering, the Volvo Teamplace.

Result

One concept was finally selected for deep

investigation and detail design. The concept

was analyzed and a full-scale prototype of a

sector of the TRF was manufactured.

In May 2009 the final concept was present-

ed together with full documentation and a well

explained manufacturing method.

16Top row, from left: Erik Åström, Stefan Sandberg (coach), Elin Söderström,

Andreas Pahkamaa. Bottom row, from left: Johan Holmqvist, Andreas

Gustafsson, Fredrik Forsberg, Erik Hjort, Johan Olofsson

Turbine Rear Frame from the ANTLE-program. Fredrik Forsberg and Erik Hjort

participating in a creative session.

Conceptual design-sketch of a TRF with separated functionality.

CAD-model of a TRF section.

1918

Volvo CE produces the world's best articulated haulers. To keep that

position, continuous R&D is required to give the machines cutting-

edge technologies that are competitive on the world market. This

year the Sirius project team helped Volvo CE with the development

of an all-new drop box. The project goals are to improve the trans-

mission in Volvo’s articulated haulers; reducing wear and tear

and fuel consumption while increasing maneuverability.

Assignment

A transfer case is basically a differential gear-

box that divides the engine torque between

the front and rear wheels. A basic differential

lacks the ability to control torque distribution,

an important factor for good traction. A locked

differential, however, results in wind-up torque

that leads to increased wear. Because of this,

the entire driveline has to be over-dimensioned.

The new transfer case therefore needs to have

the ability to dynamically adjust the torque dis-

tribution.

Background

Volvo Construction Equipment is a subsidiary

of the AB Volvo group, producing a wide range

of construction equipment including the articu-

lated hauler product line. Articulated haulers

are machines made for transporting loads over

rough terrain. The combination of all-wheel-

drive, the rough environment and a total weight

of nearly 80 metric ton sets high demands on

the driveline. One of the central parts of the

driveline is the transfer case.

Volvo CE – More Care. Built in.

Method

The group worked in accordance with Volvo’s

Global Development Process, GDP, which is a

guide for product development. The process is

divided into phases separated by “gates” that

require certain results to be achieved before

passing onto the next phase. The first step

in the process was to come up with different

ideas. After a series of brainstorming sessions,

a few concepts were picked out for further

investigation. From these suggestions a final

concept was chosen.

A concept prototype is not really useful if

it is impossible to manufacture. Therefore,

a production group made a business case

based on the concept for the transfer case.

They investigated what it would take to get

the new transfer case into serial production

in Volvo’s factory in Eskilstuna.

Top row, from left: Andreas Larsson, Magnus Brännström, Patrik Kuoppa

Second row, from left: Nils Hagström, Bertil Hagqvist, Henrik Lundh,

Pär Marklund (coach). Bottom row, from left: Emil Larsson, Johan Kettunen,

Lilian Sunna, Mikael Håkansson, Petter Kyösti

Above: Various creative tools used for concept generation and demonstrations.

Below: Drop-box casing.

Right: Volvo's largest hauler, the A40.

Rendering of the new drop-box casing design.

Articulated hauler power train. The drop-box is placed

to the right of the front axel and left of the brake disc.

A situation where 6 wheel drive and lockable differentials are useful.

Volvo CE, established in 1832, is a subsidiary of the AB Volvo

group with sales in 2007 representing 19% of group turnover.

Volvo CE is a global producer of a number of types of construc-

tion equipment with over 150 models in their present assort-

ment. This assortment includes articulated haulers, wheel

loaders, excavators, motor graders and many other types of

equipment.

Quality, Environmental Care, and of course, Safety are

the three core values of Volvo CE. These cornerstones are

always in focus when developing new products.

Results

A full-scale prototype, a demonstrator, was

constructed. The fully functional prototype will

be tested in one of Volvo’s haulers in summer

2009.

21

The main driving forces behind research at

the Division of Computer Aided Design are

total lifecycle commitment, the extended

enterprise settings, issues of sustainability,

ecology and economy, and – of course –

added value. At the division, we work within

multiple business models that include tradi-

tional transactions, business partnerships,

and extended enterprise models.

Three of these issues are closely linked

to the Sirius course; they are sustainability,

ecology and economy. Developing sustai-

nable systems in the various Sirius projects

directly translates to ecological products as

well as to industrial and economic growth.

Sirius Sustainability

One example is the Hägglunds Drives project.

In the Hägglunds Drives project, by develo-

ping a total integrated system with higher

efficiency, a smaller system can be installed

for the customer, and a smaller, more efficient

system requires less power, thus costing less

to operate and resulting in less environmental

impact. Higher efficiency means fewer los-

ses, which translates to monetary gains for

Hägglunds Drives AB as well as their custo-

mers, creating a win-win business situation.

In the aeronautics industry, for which

the Volvo Aero project is being conducted,

there are ambitious aims to create lighter,

more fuel-efficient and eco-friendly aircraft.

In such a context, arguments about sustaina-

bility, ecology and economy also apply;

perhaps even more so, due to stringent

governmental noise and pollutions require-

ments.

Another, less directly industry-oriented

example is the Shell Eco Marathon project,

where the whole approach aims at develo-

ping and demonstrating eco-friendly techno-

logy, supporting the development of future

environmentally sustainable vehicles.

Finally, in the Sandvik Coromant project,

in which the students have worked on tool

design, the results will be used to support

future AB Sandvik Coromant business sce-

narios. The right tool-interface design speeds

up tool exchange, increases productivity and

thus supports economic development. The

approach allows for more reuse of tools and

tool fittings, and thus a system with higher

sustainability.

20

The Faste Laboratory Centre for Functional Product Innovation

In June 2006, Luleå University of Technology

and the Division of Computer Aided Design

in collaboration with the Division of Fluid

Mechanics, the Division of Mechanics of Mate-

rials, the Division of Solid Mechanics and the

Division of Entrepreneurship were informed

that VINNOVA, the Swedish Agency for Inno-

vation Systems, had granted the application

to start a Vinn Excellence Centre. The

Centre, named The Faste Laboratory, is in

memory of Rolf Faste, Stanford University.

The centre’s goal is to realize Functional Pro-

duct Innovation through research and educa-

tion in collaboration with both academia and

industry. Research and education are joined

in the Sirius course.

Industrial partners are:

• AB Sandvik Coromant (SC)

• BAE Systems Hägglunds (BAE)

• Gestamp HardTech AB (GHT)

• Hägglunds Drives AB (HD)

• LKAB (LKAB)

• Volvo Aero (VA)

• Volvo Car Corporation (VCC)

• Volvo Construction Equipment (VCE)

22

The Faste Laboratory opened formally on

12th March 2007 and had by the end of

stage one, with additional funding, produced

over 100 publications in total. Due to the suc-

cessful first stage of the Faste Laboratory,

on 27th November 2008, the industrial part-

ners together with Luleå University of

Technology agreed upon continuing the re-

search in stage two starting in January 2009.

Functional Product Innovation A perspective of sustainable society forces

industrial development into new ways of con-

ducting business. For manufacturing com-

panies, a way forward is to develop physical

artefacts to provide functions that can be sold

as services. A long-term service contract

means that the provider is responsible for

delivering these functions throughout the life

cycle of the product. The product provider is

responsible for all costs for developing, manu-

facturing, supporting and continuously upgra-

ding the product. Hence, how to reengineer,

reuse and recycle the prduct becomes

important.

The vision of the Faste Laboratory is:

New methods and tools have been develo-

ped enabling functional products with opti-

mized lifecycle cost and customer value.

Central in this mission

are insights into these areas:

• Functional Product Development – contribu-

tes to the area of new processes for engine-

ering design. Closely related to the concept of

Knowledge Enabled Engineering, i.e. sharing,

managing and using knowledge related pro-

ducts and processes throughout the entire life

cycle.

• Distributed Collaborative Engineering – con-

tributes to the area of enabling, in work and

technical oriented terms, design teams to work

closely together by means of methods and

tools.

• Simulation Driven Design – contributes to

bringing several perspectives (e.g. business,

engineering and production) into early concept

design in product development.

Professor Lennart Karlsson,

Division of Computer

Aided Design and

the Faste Laboratory,

Luleå University of

Technology

Funded by the Kempe Foundations and

the Knut and Alice Wallenberg Foundation,

a research studio was designed and built at

LTU. This studio will provide unique access to

empirical studies, testing and evaluation of new

methods and tools in distributed work. The use

of the studio will contribute to research within

the Faste Laboratory.

“The Faste Laboratory at Luleå University

of Technology is one of our strongest research

environments. The close collaboration between

industry and academia within the centre is cru-

cial in order to achieve state-of-the-art results,

to improve industrial best practise, leading to

sustainable growth.”

The Figure illustrates how the Faste Laboratory supports the process from market

needs to FPI. In order to assume a total life-cycle commitment for a functional

product, large company networks i.e. extended enterprises, are needed where

the business risk is shared. The figure further shows the required innovative

capabilities needed for FPI.

Industry and academia in collaborationLars-Ola Normark

Sirius Engineer 2001/02

Volvo Aero Corporation

For me, the Sirius experience was a perfect match. During

the fourth year of study, I felt the need to connect all the

theory to something more business oriented, with all the

new constraints that follow. Being a long-time aviation

enthusiast, it was an obvious choice when I got the oppor-

tunity to work closely with Volvo Aero in developing a jet

engine component.

The experience took the team through the complete

development cycle. Now, following 7-8 years of working in

the aerospace business, I am still amazed at how well the

course reflected the actual product development cycle at

Volvo Aero. A clear sense of professionalism pervaded the

entire programme, both from an academic standpoint and

from the company Volvo Aero Corporation.

Sirius led further to my master thesis at Volvo Aero and

subsequently to employment. I had the great opportunity to

start out as a trainee, where I got to know both the company

and its partners worldwide. In my current role as a lead

structural engineer, I work with the development of new effi-

cient products for the industry. Reflecting over my current

scope of work, it is quite interesting that I now on a day-to-

day basis work with tasks essentially the same as I did dur-

ing the Sirius programme.

Per Söderberg

Manager Research

& Advanced Engineering

Volvo Construction

Equipment AB

Volvo CE has a long history of collaboration with LTU in

different forms including a good number of successful

recruitments and involvement in common research projects.

During 2008/2009 we will also be involved in the Sirius

project. This increased involvement is based on our strong

belief that collaboration between industry and academia will

be a critical factor in the successful provision of knowledge

and competence in the future. We also see the potential for

small, incremental as well as larger, significant innovations

spawning from the Sirius project due to the “out-of-the-box”

creative thinking the students bring to the industrial case.

An additional “win-win” situation that we noticed early

on in the project is that while the real case environment pre-

pares the students for their first job experience, the Volvo

staff connected to the project also receive effective on-the-

job training. We develop our own competence, for example,

by learning more about distributed collaboration and how

to specify work scopes to external R&D sites. Based on this

we already regard our involvement in Sirius as a success

and we hope that the Sirius project will also in the future

be a key ingredient in Volvo CE’s strategy for long-term

competitiveness by creating innovative solutions, develop-

ing people and enhancing competence on all educational

levels.

23

Kajsa Björn

Sirius Engineer 2007/08

Etteplan Industry

Sirius is not a course you take; it’s a course you live.

The commitment, cooperation, inventiveness, and the

knowledge that the students have, give, and earn lack

comparison. Theories and methods are developed into

reality and the goal to finish the project successfully soon

becomes much more important than grades.

Being a part of the successful university-embracing project

“Baldos” did not only give knowledge in designing an

incredibly fuel-efficient vehicle and all the challenges it led

to. Baldos presented challenges when bringing various

opinions and experiences towards a common goal; when

prioritizing between time, cost, and complexity to solve all

possible problems in an effective and sustainable manner.

A good conclusion would be “thinking outside the box”.

What makes Sirius unique are its width and its similarity

to real projects in working life – everything from technol-

ogy, planning, and business dealings is managed by the

students. On a personal level, Sirius made me more self-

confident and increased my self-esteem, the other students

and I were put to constant challenges and were trained to

recognize our own strengths and weaknesses.

Today I work as a technical consultant at Etteplan,

where the ability to adapt to different situations and groups

is essential. To me, Sirius isn’t over, the benefits are for life.

Martin Jonsson

Manager Research & Development

Gestamp HardTech AB

Gestamp HardTech has a long history of advanced research

activities together with Luleå University of Technology.

One example is the DYNSYS research project, where

the goal is to develop dynamic CAE sub-models with good

correlation with full vehicle simulation and crash testing of

bumpers. After an extensive research programme including

test cart and full vehicle crash testing, full vehicle simula-

tions and theoretical modelling an advanced dynamic sub-

model has been implemented.

Still, there was a competence gap that needed to be

closed; our old test cart is totally stiff and cannot repeat

the dynamic behaviour of the crash simulation. The Sirius

student team took the challenge to develop and design an

advanced test cart with adjustable dynamic behaviour.

The engineering task has been solved in a very good

way and the advanced dynamic test cart will soon be built.

It will be the first of its kind on the market and a very impor-

tant tool for our bumper development team.

The Sirius programme has been a new and very posi-

tive experience for us. We will certainly continue with new

projects.

Industry and academia in collaborationFOTO: ATELJÉ GRODAN, LULEÅ

Sirius students 2008/09

Top row, from left: Carl-Emil Bengtsson (HDAB), Emil Larsson (VCE), Nils Hagström (VCE), Per Nilsson (Eco Marathon), Petter Ulfberg (GHT), Jens Hardell (coach), Andreas Pahkamaa (VAC), Jens Carlevi (coach), Johannes Carlsson (Eco Marathon),

Stefan Sandberg (coach), Magnus Karlberg (Coordinator), Magnus Löfstrand (coach)

Second row, from left: Björn Backe (HDAB), Andreas Lindberg (GHT), Joakim Winsa (HDAB), Pär Marklund (coach), Henrik Andersson (Eco Marathon), Bertil Hagqvist (VCE), Per Mattson (SC), Magnus Persson (SC), Mikael Håkansson (VCE),

Fredrik Forsberg (VAC), Henrik Lundh (VCE), Patrik Kuoppa (VCE), Peter Åström (coach), Tomas Furucrona (SC)

Third row, from left: Pär Mikaelsson (GHT), Erik Åström (VAC), Jonas Pelli (HDAB), Emil Larsson (VCE), Johan Kettunen (VCE), Fredrik Löfgren (Eco Marathon), Andreas Gustafsson (VAC), Petter Kyösti (VCE), Johan Olofsson (VAC), Johan Holmqvist (VAC),

Filip Berglund (GHT), Lennart Karlsson (Professor)

Bottom row, from left: Johan Nilsson (GHT), Jonas Pavasson Hatta (GHT), Mikael Nybacka (coach), Elin Söderström (VAC), Mojgan Mohseni (SC), Anna Söderlind (SC), Lu Juan Juan (SC), Lilian Sunna (VCE), Rebecca Andersson (SC), Emma Rydh (SC),

Jimmy Björnström (HDAB), Erik Hjort (VAC), Magnus Brännström (VCE)