austempered ductile iron for successfully lightweight...

Austempered Ductile Ironfor successfully lightweight designed components

Oscillating suspension arm for special vehicles

In cooperation with Industrie Cometto S.p.A.

ADI JS/800-10

Substitution of a welded assembly

Increased load capacity of the vehicle

Increased competitiveness

Hannover, 14TH April 2015

Company overview

What’s ADI

ADI Advantages

ADI Applications

Oscillating Arm for Special Vehicles

Hannover, 14TH April 2015

Austempered Ductile Ironfor successfully lightweight designed components

Company OverviewGeneral information

Hannover, 14TH April 2015

Minerbe (Verona, Italy)

60km from Verona Airport120km from Venice Airport240km from Milano Airport

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Company Overview

1931 Foundation Year

General information

Hannover, 14TH April 2015

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Company OverviewGeneral information

Hannover, 14TH April 2015

220 Employees

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Company OverviewGeneral information

Hannover, 14TH April 2015

70.000 smq Total Surface Area50% covered

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Company OverviewGeneral information

Hannover, 14TH April 2015

22.000 Ton Foundry Capacity

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Zanardi Facilities

MACHINING SHOP

FOUNDRY

CORE SHOP

PAINTING SHOP

LABORATORY FINAL TESTING

AUSTEMPERING HEAT TREATMENT

ENGINEERING DEPARTMENT

Hannover, 14TH April 2015

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Zanardi Facilities

Design and Co-Design

Engineering Department

ProE CAD & ProE FEM Magmasoft

Hannover, 14TH April 2015

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Zanardi FacilitiesFoundry

Weight Range: 1 – 130 kg

Moulding LineDimensions: 710x900x(250+350)mm

Hannover, 14TH April 2015

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Zanardi FacilitiesFoundry

3 Melting induction furnace

28 ton per furnace

Hannover, 14TH April 2015

Melting Plant

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Zanardi FacilitiesFoundry

Pouring LineWith automatic Transfer Ladle

Hannover, 14TH April 2015

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Zanardi FacilitiesAustempering Heat Treatment

3 AFC-Holcroft UBQA

Equipment

All our austempering treatment has been done internally since 2001.

Hannover, 14TH April 2015

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Zanardi Facilities

All our austempering treatment has been done internally since 2001.

10.000 tonHeat Treatment Capacity

Austempering Heat Treatment

Hannover, 14TH April 2015

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Zanardi Facilities

All our austempering treatment has been done internally since 2001.

Additional ServiceHeat Treatment in Subcontracting

Austempering Heat Treatment

Hannover, 14TH April 2015

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Zanardi FacilitiesMachining Shop

Nr. 3 Vertical Lathe Hyundai Hit V5Nr. 4 Robotised platformNr. 2 Workstation

Hannover, 14TH April 2015

Machining

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Zanardi Facilities

Chemical & Mechanical Lab.

Laboratory Final Testing

Hannover, 14TH April 2015

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Zanardi Facilities

Testing machines for fatigue

Laboratory Final Testing

Hannover, 14TH April 2015

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19Company Overview

Standard MaterialsDuctile Iron

Materials

Hannover, 14TH April 2015

20Company Overview

Standard MaterialsDuctile Iron

Austempered Ductile Iron (ADI)

Materials

Hannover, 14TH April 2015

21Company Overview

Standard MaterialsDuctile Iron

Austempered Ductile Iron (ADI)

NEW Austempered Materials

Austempered Grey Iron (AGI)

Materials

Hannover, 14TH April 2015

22Company Overview

Standard MaterialsDuctile Iron

Austempered Ductile Iron (ADI)

NEW Austempered Materials

Austempered Grey Iron (AGI)

Austempered Steel

Materials

Hannover, 14TH April 2015

23Company Overview

Standard MaterialsDuctile Iron

Austempered Ductile Iron (ADI)

NEW Austempered Materials

Austempered Grey Iron (AGI)

Austempered Steel

Zanardi Patented Materials

ADI Wear Resistance (ADIWR)

Materials

Hannover, 14TH April 2015

24Company Overview

Standard MaterialsDuctile Iron

Austempered Ductile Iron (ADI)

NEW Austempered Materials

Austempered Grey Iron (AGI)

Austempered Steel

Zanardi Patented Materials

ADI Wear Resistance (ADIWR)

Isothermed Ductile Iron (IDI)

Materials

Hannover, 14TH April 2015

25What’s ADIAustempered Ductile Iron

Ductile Iron and Alloys

Perlitic and Ferritic Matrix obtained AS-CAST

Heat Treatment in Salt Bath

Austempered Ductile Iron

Acicular Ferrite in stabilized austenitic structure

Ductile Iron

ADI

Austempering

Hannover, 14TH April 2015

Austempering Cycle 26

Hannover, 14TH April 2015

27What’s ADI

LIGHTNESS

Advantages

Hannover, 14TH April 2015

28What’s ADIAdvantages

COMPLEX DESIGN SHAPES

Hannover, 14TH April 2015

What’s ADIAdvantages

Hannover, 14TH April 2015

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30What’s ADIAdvantages

WEAR RESISTANCE

Hannover, 14TH April 2015

31What’s ADI

FATIGUE

Advantages

Hannover, 14TH April 2015

32What’s ADIAdvantages

RECYCLABILITY

Hannover, 14TH April 2015

33Market

Earth Movement

Trucks, Busses and Coaches

Gears & Transmissions

Agriculture

Automotive Concrete and Mining Plant

Railway Compressors, hydraulics and oleodynamics

Hannover, 14TH April 2015

34MarketAutomotive

STATIONARY BRAKE PLATESADI1050-6Raw weight: 3 - 4 Kg

STATIONARY BRAKE TONGSBEARINGSADI1050-6 Raw weight: 2 - 3 Kg

Hannover, 14TH April 2015

Increased durability

Increased durability

35Market

SUSPENSION ARM ADI900-8Raw weight: 7 Kg

Automotive

STEERING KNUCKLESADI900-8Raw weight: 9 Kg

Hannover, 14TH April 2015

Material saved -1,2Kg

Material saved -2,1Kg

36MarketTrucks, Busses and Coaches

SUSPENSION FOR HEAVY TRUCKSADI800-10 o IDI Raw weight: 70 - 75 Kg

SUSPENSION ARMS FOR BUSESADI1050-6 Raw weight: 35 - 40 Kg

Hannover, 14TH April 2015

Improved durability

Improved durability

37Market

PLANET CARRIER SOLID SHAFT ADI800-10 & ADI900-8Raw weight: 30 - 150 Kg

Gears & Transmissions

Hannover, 14TH April 2015

PLANETARY HOUSING ADI800-10 & ADI900-8 Rawweight: 5 - 70 Kg

Improved durability

Improved durability

38Market

SPINDLE ADI1050-6 Raw weight: 90 Kg

Agriculture

CLUTCH DRUMADI1050-6 Raw weight: 3 - 5 Kg

Hannover, 14TH April 2015

Weight reduction -15KgMaterial saved -35 Kg

Reduced weight and costs

39Market

ROTATORADI900-8 Raw weight: 20 Kg

Agriculture

COUPLING SYSTEM ADI1050-6 Raw weight: 10 - 15 Kg

Hannover, 14TH April 2015

Improved durability

Reduced weightImproved durability

40Market

U/C SPROCKET ADI1050-6; ADI1200-3; ADI1400-1; ADI1600-1 Raw weight: 3 - 40 Kg

Earth Movement

Hannover, 14TH April 2015

U/C CHAIN LINK FOR TRACK LAYER ADI1050-6 Raw weight: 1 - 7 Kg

Wear resistance

Wear resistance

41Market

CONCRETE PUMP ROTOR ADI1600-1; ADIWR Raw weight: 3 - 5 Kg

Concrete and Mining Plant

Hannover, 14TH April 2015

HAMMER ADI1050-6; ADI1400-1 Raw weight: 5 - 70 Kg

Wear resistance

Wear resistance

42MarketConcrete and Mining Plant

Hannover, 14TH April 2015

COVER ADI1600-1; ADIWR Raw weight: 2 - 4 Kg

COVER AND PLATE FOR MIXER ADI1600-1; ADIWR Raw weight: 6 - 10 Kg

Wear resistance

Wear resistance

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PUMP HEAD IDI Raw weight: 2 - 70 Kg

PUMP CASE AGI Raw weight: 50 - 150 Kg

Compressors, Hydraulics and Oleodynamics

Market

Hannover, 14TH April 2015

Wear resistance

Improved durability

Oscillating Suspension ArmPartnership

Hannover, 14TH April 2015

Industrie Cometto S.p.A.Modular Vehicle manufacturerLifting platformsTheoretically infinite axlesSeveral tons of load capacityChemical plantsWind power generationOff-shore platforms

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Component Description

Hannover, 14TH April 2015

Oscillating suspension armfor MSPE VehicleHydraulic suspensionHeight change up to 700 mm4 axles and 6 axles40 ton/axle

Project target increase loadcapacity up to 50 ton/axle +25%

Oscillating Suspension Arm 45

Design Solutions

Hannover, 14TH April 2015

40 ton/axle versionWelded assembly of 8 parts

Oscillating Suspension Arm

Material RP0.2

[N/mm2]

Rm

[N/mm2]

A5

S690QL 700 780-930 14 %S355JR 315 470-630 20 %

S355JR

S690QL

Total weight 99 KgDue to narrow spaces, it wasnot possible to increaseresistant sections of thecomponent to reach50 ton/axle

Substitute S690QL with S890QL

Options

Substitute welded assembly with one single ADI casting

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Material selection

Hannover, 14TH April 2015

Oscillating Suspension Arm

Selection criteriaTensile behaviorFatigue behaviorMachinabilityFinal component cost

WELDEDASSEMBY

ADICASTING

Material RP0.2

[N/mm2]

Rm

[N/mm2]

A5

S890QL 900 940-1100 12 %

JS/800-10 500 800 10 %

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Tensile propertiesOscillating Suspension Arm

Hannover, 14TH April 2015

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Tensile propertiesOscillating Suspension Arm

Hannover, 14TH April 2015

ADI 800

WM

BM-LT

PW

BM-TL

S890QLPW: Plane samplesBM-TL: Base material taken in orthogonal direction by welding beamBM-LT: Base material taken in parallel direction by welding beamWM: Samples taken on welding beam

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Hannover, 14TH April 2015

Tensile propertiesOscillating Suspension Arm

G25CrMo4

42CrMo4 Wrought

ADI JS/800-10

ADI JS/1050-6

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FEM Calculations

Hannover, 14TH April 2015

Oscillating Suspension Arm

WELDEDASSEMBY

ADICASTING

40 ton version

50 ton version

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Fatigue properties

Hannover, 14TH April 2015

Oscillating Suspension Arm

DI

DI

DI

IDI ADI

ADI42CrMo4 QT

S890QL BASE

S890QL JOINT

S690QL BASEy = 0,6985 HB + 207,3R2 = 0,9819

200

250

300

350

400

450

500

170 270 370 470 570 670 770 870 970

Δσ 0

/2

[N

/mm

2]

RP0.2 [N/mm2]

Separately cast specimens Si2.6%; Mn0.15%; 200 Nod/mm2

Machined test probes - Ø6,5 - Rotating Bending R= -1 - PS 50% - Run Out 5 Million Cycles - Short Stair case

S690QL and S890 are taken from literature work www.dvs-ev.de and converted from PB to RB with 0.8 load mode factor

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Threshold Crack Initiation Value

Hannover, 14TH April 2015

Oscillating Suspension Arm 53

DI

DI

IDIADI

ADI

42CrMo4 QT

y = 0,0983HB - 11,929R2 = 0,9939

10

12

14

16

18

20

22

24

170 270 370 470 570 670 770 870 970

DK

TH

[MPa

* m

^0,5

]

RP0.2 [N/mm2]

Separately cast specimens Si2.6%; Mn0.15%; 200 Nod/mm2

Machined test probes - Ø6,5 - Rotating Bending R= -1 - PS 50% - Run Out 5 Million Cycles - Short Stair case

Threshold Crack Initiation Value

Hannover, 14TH April 2015

Oscillating Suspension Arm 54

Fatigue Comparison with cast steel

Hannover, 14TH April 2015

Oscillating Suspension Arm 55

ADI JS/900-8/C

STEEL CASTING G25CrMo4QT

Hannover, 14TH April 2015

Fatigue Comparison with cast steelOscillating Suspension Arm 56

10

100

1000

α2a

Δσg, thMachined Kitagawa Curve

Machined El Haddad Curve

Un-Machined Kitagawa Curve

a0 Bulk Estimated a0 Layer = 300 μm

ΔKTH =16,10 [Mpa m0,5]KL Layer without defects = 1.6 – 1.8

Hannover, 14TH April 2015

Fatigue in case of casting skinOscillating Suspension Arm 57

Technology comparison

Hannover, 14TH April 2015

Oscillating Suspension Arm

Complex manufacturingPreparation machining operationsAdditional heat treatmentsControls of welded jointsLimited fatigue resistanceHigh stress concentration on joints

WELDEDASSEMBY

ADICASTING

Easier manufacturingReduced machining operationsNo additional treatmentsFatigue resistanceOptimized design to avoid stress concentrationsEffect of casting skin to be considered

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Hannover, 14TH April 2015

ConclusionsOscillating Suspension Arm

Oscillating suspension armADI casting was successfully adopted

Increasing 25% the load capacity

with only 2% more weight

Better fatigue behavior and

good machinability

Cost reduction thanks to easier

manufacturing process

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Thanks for Your attention

Light weight Solutions

Hall 6, Stand D44

Contactsstaff@zanardifonderie.comPh: +39 0442 647397 Address

Via Nazionale, 337046 Minerbe, (Verona)

Italy

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