Transmission and Driveline Development and Their Components

This proposal is directed at a fundamental change in military trucks by designing driveline systems as a complete lightweight module manufactured from selectively chosen lightweight components. Current driveshafts, differentials, transfer cases, axles, and brake systems are typically bolted together of cast iron and steel components. If a lightweight aluminum part is included, it is typically substituted for an iron component. The identical mating shape is required for bolting, so the lightweight part is not truly optimized. Therefore, designing an entire module of the best lightweight materials is the only way to truly optimize the system. This allows optimized designs, multi functional shapes, and advanced materials to integrate for a lightweight system. The proposal will design a complete driveline module of advanced materials to demonstrate the weight reduction of this concept. To limit the size of a program for a Phase I SBIR, GS Engineering will design a side plate, axle structure and differential housing as a module. Advanced lightweight materials including magnesium, magnesium metal matrix composites, and aluminum metal matrix composites will be used to optimize the weight of the entire system. This concept can be applied to any military truck, from the FTTS to retrofitting existing HEMTTs and FMTVs. GSE has chosen to design a system for the HEMTT A3 as the platform as it has a current weight reduction program. Oshkosh Truck Corporation will cooperate on this program by providing design information, loading conditions, and engineering support for the HEMTT A3 upgrade.