NAVISTAR TMS 2008-2000 Equalizer Beam Castings (Revision F-1).pdf

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1、INTERNATIONAL TRUCK AND ENGINE CORPORATION TMS (TRUCK MATERIAL SPECIFICATION) NUMBER: TMS- 2008 ITITLE: Eaualizer Beam Castings IREVZSZOAJ :F - 1 I WRiTTEN/EDITED BY: Materials Engineering APPROVED BY: DATE ISSUED Materials Engineering August 2000 befereme: File 03-1 Keywords: Walking Beams; Suspens

2、ion I 1.0 APPLICATION This specification covers International requirements for nodular iron equalizer “walking“ beam castings used in the rear suspension of heavy duty trucks. 2.0 SCOPE This specification covers the requirements for mechanical properties, 3 categories of surface discontinuities, ide

3、ntification, quality, source approval and quality control, and shipping. 3.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest issue of all referenced standards shall apply. The following standards, specifications and regulations are referenced in this specification. Quality System Standard

4、 QS-9000 (IS0 9001) INTERNATIONAL CEMS E- 1 O INTERNATIONAL IQR Quality Standard INTERNATIONAL Manufacturing Standard D-13 CFR Title 29, Part 1910 4.0 REOUIREMENTS Castings shall conform to all requirements for Grade 6503, CEMS E-10 with the following additions and exceptions: 4.1 Mechanical Propert

5、ies 4.1.1 Tensile bars machined from castings shall exhibit a minimum tensile strength of 515 MPa (75 O00 psi) and a minimum yield strength (0.2% offset) of 345 MPa (50 O00 psi). Tensile bars shall be taken from the intersection of the flange and the webs near the center bore on the side opposite th

6、e gate pad (See Figure 1). This is an additional requirement to those specified in E-10. 4.1.2 Hardness shall be BHN 197-269 (3000 kg, 10 mm ball) and shall be measured on each casting on the cope side of the center bore and on either the cope or drag side of either end bore. This requirement supers

7、edes hardness values specified in CEMS E- 10. This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 02000 International Truck and E

8、ngine Corporation AUGUST 2000 Page 1 of 5 NUMBER: TMS- 2008 4.1.3 Castings shall exhibit a minimum fatigue life of 70,000 cycles. Fatigue testing shall be performed using an entire casting as the test specimen. Loads experienced by the casting during fatigue testing shall correspond to the suspensio

9、n rating of the equalizer beam, as indicated in the following table: TITLE: REVISION: Equalizer Beam Castings F-1 Suspension Rating Of Equalizer Beam Range Of Loads Experienced At Centerline Of Center Bore In Fatigue Test kN (lb0 Kn (lb0 151 (34,000) 169 (3 8,000) 196 (44,000) +30 to +302 +34 to +33

10、8 +36 to +355 (+6,800 to +68,000) (+7,600 to +76,000) (+8,000 to +80,000) 4.2 Surface Discontinuities Figure 2 defines the flange and web surfaces of the beam. In addition to the general requirements regarding cast surfaces stated in CEMS E-10, the flange and web surfaces shall meet the-following re

11、quirements regarding visual discontinuities: 4.2.1 Categorv 1 Discontinuities Cracks, shrinkage porosity, cold shuts, trapped sand, trapped slag. 4.2.1.1 Tension And Compression Flanges From Centerline To Centerline Of End Bores All protruding discontinuities shall be ground flush with the casting s

12、urface; grinding shall be in a longitudinal direction. 4.2.1.2 Discontinuities up to 1.5 mm (U16 inch) in depth are permissible provided there is visual evidence that the bottom of the discontinuity does not extend below this depth. When this visual evidence is absent, a small diameter carbide or si

13、milar cutting surface grinder shall be used to probe directly into the discontinuity. 4.2.1.3 If probing confirms that the discontinuity is no deeper than 1.5 mm (U16 in) max, the probe grinding need not be blended out. 4.2.1.4 If probing confirms that the discontinuity is 1.5 to 3 mm (U16 to 1/8 in

14、) in depth, the beam may be salvaged only by employing a large diameter grinding wheel to blend the area of the discontinuity into the surrounding casting surface. 4.2.1.5 Blending shall be done in a longitudinal direction and shall be achieved within a width of 25 to 38 mm (1 to 1-1/2 in) and a len

15、gth of 100 to 150 mm (4 to 6 in). 4.2.1.6 If probing confirms that the discontinuity is greater than 3 mm (1/8 in) in depth, the casting shall be rejected. This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corpora

16、te Technical Standards. Suppliers are required to assume all patent liability. 02000 International Truck and Engine Corporation AUGUST 2000 Page 2 of 5 NUMBER: TMS- 2008 4.2.1.7 No more than six discontinuities in the size range 1.5-3 mm (U16 to 1/8 in) in depth may be blended out on each flange of

17、any one casting. If the casting exhibits more than six of these kinds of discontinuities on any one flange, the casting shall be rejected. 4.2.1.8 To avoid excessive stock removal at any particular location, discontinuities to be blended out on the same flange must be separated by 50 mm (2 in) min,

18、of sound metal and there can be no more than one discontinuity on any plane perpendicular to the centerline of the beam. Discontinuities located on opposite flanges (tension and compression) must be on planes (perpendicular to the centerline) that are separated by 50 mm (2 in) min, of sound metal. 4

19、.2.1.9 Both sides of Web From Centerline To Centerline of End Bores Same requirements as on flanges, except the maximum allowable depth of discontinuity is 5 mm (3/16 in) and removal of these by grinding is optional. TITLE: REVISION: Equalizer Beam Castings F-1 4.2.2 Categ;orv 2 Discontinuities - Ga

20、s Porositv 4.2.2.1 Tension And Compression Flanges From Centerline To Centerline Of End Bores Same requirements as for Category 1, except clustered pinhole porosity may not exceed 3 pores/cm2 (20 pores/in2); if this is exceeded, the casting shall be rejected. 4.2.2.2 Both Sides Of Web From Centerlin

21、e To Centerline Of End Bores Same requirements as on flanges, except that the maximum allowable depth of discontinuity is 5 mm (3/16 in) and removal of these by grinding is optional. 4.2.3 Categ;orv 3 Discontinuities - Parting; Line Finish All flash on the casting parting line greater than 1.5 mm (U

22、16 in) in height shall be removed by longitudinal grinding. Any irregular or sharp-edged flash, regardless of height, shall be removed by longitudinal grinding. 4.2.3.1 In addition to the general requirements regarding machined surfaces stated in CEMS E-10, discontinuities shall not exceed 1.5 mm (l

23、/16 in) in depth or 3 mm (1/8 in) in width. 4.3 Identification 4.3.1 The letters 6C (formerly NC) shall be permanently and legibly marked on all as-cast nodular iron equalizer beams; if the castings are normalized, the letters 6N (formerly NN) shall be shown. 4.3.2 The flange of the casting containi

24、ng the gates and risers shall be identified on both sides of the web with the raised letters UP and an arrow pointing to that flange. Since the beam is symmetrical, this easily enables Manufacturing to install the beam in the vehicle such that the flange with the gates and risers is on the upper (co

25、mpression) side. 4.4 Processing; and Inspection 4.4.1 Equalizer beams shall not be straightened. This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume al

26、l patent liability. 02000 International Truck and Engine Corporation AUGUST 2000 Page 3 of 5 NUMBER: TMS- 2008 4.4.2 Each casting shall also be inspected by appropriate nondestructive test methods to insure that the nodularity requirements of CEMS E- 10 are met. TITLE: REVISION: Equalizer Beam Casti

27、ngs F-1 5.0 OUALITY All production supplied shall be clean and free from dirt, oils, sharp edges, or defects harmful to product performance. 6.0 SOURCE APPROVAL AND OUALITY CONTROL 6.1 Supplier Requirements Suppliers must conform to the requirements of the INTERNATIONAL IQR Standard which includes c

28、onformance to the QS-9000 (IS0 9001) Quality System Standard. A mutually acceptable Quality Control Plan as described therein is required for source approval to the requirements of this specification. 6.2 Approval Parts supplied against contracts or purchase orders citing this specification shall be

29、 equivalent in all respects to those samples which were approved by the purchaser. No changes in formulation or processing practices are permitted without approval. In the event that changes in material, properties, processing practices, construction, color, or labeling of the product are required,

30、the supplier shall notify Truck Development and Technology Center and International Purchasing and Supplier Development of the proposed change(s). Test data indicating conformance to all requirements of this specification, test samples, and new or amended or updated Material Safety Data Sheet(s) (MS

31、DS), in accordance with CFR Title 29, Part 1910 shall be submitted with the request for change. 6.3 Process Control The supplier shall either perform and report results of tests on specific lots of parts produced or provide statistical evidence of the lot having been produced in a state of statistic

32、al control and with a process capable of providing all required properties. The part supplier and the plant metallurgist andor the quality control manager of the using International plant may determine testing and reporting requirements on specific products. 7.0 SHIPPING, PACKING AND IDENTIFICATION

33、Loading, packing and identification shall be in accordance with Manufacturing Std. D-13. 8.0 DESIGNATION ON DRAWINGS Material description on drawings and purchase orders shall be: Nodular Iron Per TMS-2008 This document is restricted and may not be sent outside International Truck and Engine Corpora

34、tion or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 02000 International Truck and Engine Corporation AUGUST 2000 Page 4 of 5 NUMBER: TMS- 2008 Figure 1 TITLE: REVISION: Equalizer Beam Castings F-1 THAN TENC;IJ,F BAR LOrATTn

35、N 2 INCHES FROM CENT& RORE. Figure 2 FLANGE (TYPICAL) This document is restricted and may not be sent outside International Truck and Engine Corporation or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 02000 International Truck and Engine Corporation AUGUST 2000 Page 5 of 5