Case Study: Oil Pump Assembly

Process: Conventional Press & Sinter (PM)

Material: Upper and Lower Covers FD-0200 at 7.0 g/cm³

                Gerotor Set FD-0208 at 7.0 g/cm³

                Pump Core Frame FD-0200 at 7.0 g/cm³

                Bushing FC-0200 at 6.6 g/cm³

Reduced NVH (noise, vibration, and harshness)

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End Use and Function

This innovative oil pump assembly is used in a cost-effective dual-clutch transmission, representing the first complete integration of an electric motor in a hybrid electric vehicle.

Fabrication

The assembly includes upper and lower covers, a gerotor set, a pump core frame, and a copper steel bushing, all made from high-density materials. The geometrical tolerances on the gerotor were very tight, with a thickness tolerance range of 10 μm and flatness of 3 μm, which required a precise grinding process.

Redesigning from die-cast aluminum to PM components improves pump performance, reduces NVH scattering, and lowers costs.

Results

Manufacturing and assembling all components in a single location eliminates the need for disposable packaging and lowers shipping costs, resulting in reduced CO2 emissions.