Austempered Ductile Iron for successfully lightweight ...files.messe.de/abstracts/61099_ADI_for_Successfully_Lightweight... · 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


Austempered Ductile Ironfor successfully lightweight designed components

Company OverviewGeneral information


Minerbe (Verona, Italy)

60km from Verona Airport120km from Venice Airport240km from Milano Airport

3

Company Overview

1931 Foundation Year

General information


4



220 Employees

5



70.000 smq Total Surface Area50% covered

6



22.000 Ton Foundry Capacity

7

Zanardi Facilities

MACHINING SHOP

FOUNDRY

CORE SHOP

PAINTING SHOP

LABORATORY FINAL TESTING

AUSTEMPERING HEAT TREATMENT

ENGINEERING DEPARTMENT


8

Zanardi Facilities

Design and Co-Design

Engineering Department

ProE CAD & ProE FEM Magmasoft


9

Zanardi FacilitiesFoundry

Weight Range: 1 – 130 kg

Moulding LineDimensions: 710x900x(250+350)mm


10


3 Melting induction furnace

28 ton per furnace


Melting Plant

11


Pouring LineWith automatic Transfer Ladle


12

Zanardi FacilitiesAustempering Heat Treatment

3 AFC-Holcroft UBQA

Equipment

All our austempering treatment has been done internally since 2001.


13

Zanardi Facilities


10.000 tonHeat Treatment Capacity

Austempering Heat Treatment


14

Zanardi Facilities


Additional ServiceHeat Treatment in Subcontracting

Austempering Heat Treatment


15

Zanardi FacilitiesMachining Shop

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


Machining

16

Zanardi Facilities

Chemical & Mechanical Lab.

Laboratory Final Testing


17

Zanardi Facilities

Testing machines for fatigue

Laboratory Final Testing


18

19Company Overview

Standard MaterialsDuctile Iron

Materials


20Company Overview


Austempered Ductile Iron (ADI)

Materials


21Company Overview



NEW Austempered Materials

Austempered Grey Iron (AGI)

Materials


22Company Overview





Austempered Steel

Materials


23Company Overview





Austempered Steel

Zanardi Patented Materials

ADI Wear Resistance (ADIWR)

Materials


24Company Overview





Austempered Steel

Zanardi Patented Materials

ADI Wear Resistance (ADIWR)

Isothermed Ductile Iron (IDI)

Materials


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


Austempering Cycle 26


27What’s ADI

LIGHTNESS

Advantages


28What’s ADIAdvantages

COMPLEX DESIGN SHAPES


What’s ADIAdvantages


29


WEAR RESISTANCE


31What’s ADI

FATIGUE

Advantages



RECYCLABILITY


33Market

Earth Movement

Trucks, Busses and Coaches

Gears & Transmissions

Agriculture

Automotive Concrete and Mining Plant

Railway Compressors, hydraulics and oleodynamics


34MarketAutomotive

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

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


Increased durability

Increased durability

35Market

SUSPENSION ARM ADI900-8Raw weight: 7 Kg

Automotive

STEERING KNUCKLESADI900-8Raw weight: 9 Kg


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


Improved durability

Improved durability

37Market

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

Gears & Transmissions


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


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


Improved durability

Reduced weightImproved durability

40Market

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

Earth Movement


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


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

Wear resistance

Wear resistance

42MarketConcrete and Mining Plant


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


Wear resistance

Improved durability

Oscillating Suspension ArmPartnership


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

44

Component Description


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


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

46

Material selection



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


48



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

49



G25CrMo4

42CrMo4 Wrought

ADI JS/800-10

ADI JS/1050-6

50

FEM Calculations



WELDEDASSEMBY

ADICASTING

40 ton version

50 ton version

51

Fatigue properties



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

52

http://www.dvs-ev.de/

Threshold Crack Initiation Value



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



Fatigue Comparison with cast steel



ADI JS/900-8/C

STEEL CASTING G25CrMo4QT


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


Fatigue in case of casting skinOscillating Suspension Arm 57

Technology comparison



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

58


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

59

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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