austempered ductile iron for successfully lightweight...
TRANSCRIPT
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
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Zanardi FacilitiesFoundry
Weight Range: 1 – 130 kg
Moulding LineDimensions: 710x900x(250+350)mm
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Zanardi FacilitiesFoundry
3 Melting induction furnace
28 ton per furnace
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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
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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
[email protected]: +39 0442 647397 Address
Via Nazionale, 337046 Minerbe, (Verona)
Italy
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