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In order to reduce friction and predict wear of the sliding part, it is important to determine the oil film thickness of particular area. A sensor or similar device must be attached to the sliding surface to detect the oil film thickness. However, a sensor could not be attached, due to the lack of space on contact surface, and moreover there was no method to secure the sensor on contact surface at that time. A several-micrometer-thin-film sensor was installed on a sliding surface to attempt measurement, but since the sensor was attached on a contact surface, wear occurred immediately and data was unable to be obtained. To accomplish above issue, we developed a protective layer with excellent wear-resistance that successfully extended the measurement time by protecting the thin-film sensor.

The housing accounts for a large portion of the overall weight of automotive transmissions, making it a part with a high need for weight reduction. In addition, while the application of topology optimization for the purpose of reducing weight and increasing rigidity is nearing a practical level, there are no reports yet of methods for effectively applying topology optimization to complex shapes such as transmission housings. Therefore, this study developed a topology optimization method as a tool for use in the design of lightweight and high-rigidity automotive transmission housings. The modeling method uses a double-layered structural mesh so that topology optimization calculations can be performed for transmission housings with a hermetic structure. This method realized a reduction in weight while still meeting the target rigidity values for transmission housings.