Mechanical Technology July 2015

⎪ Nota bene ⎪

World’s first plastic rear axle transmission crossbeam

T he world’s first plastic transmis- sion crossbeam for a rear axle subframe has been developed by ContiTech Vibration Control and BASF for the S‑Class Mercedes-Benz. The crossbeam is made from the en- gineering plastic Ultramid ® A3WG10 CR, a specialty polyamide from BASF that is specially reinforced and optimised to withstand high mechanical loads. Compared to the previous beam made from die-cast aluminium, this highly durable component offers a weight sav- ing of 25%, better acoustics as well as excellent mechanical properties – even at high temperatures – and it conforms to the latest crash-test requirements. The design expertise embedded in BASF’s simulation tool Ultrasim ® made a major contribution to realising these properties. The plastic load-bearing structural component meets all the requirements for the static and dynamic loads that act on a transmission beam: As a central component of the rear axle, the beam counteracts torque transferred from the engine to the transmission and bears a constant share of the differential load. For all of the reasons above, the Ultramid crossbeam is now used in vehicle designs from

Mercedes-Benz with all-wheel drive, with the exception of the AMG cars. To replace aluminium in this de- manding, crash-relevant application, the plastic has to meet high mechanical requirements. The Ultramid crash resis- tant plastic used, which is 50% glass fibre reinforced, shows optimum strength and rigidity and a low tendency to creep under constant loading. In addition, the material has to withstand high bending torques and exhibits good NVH (noise, vibration, harshness) performance. “The new rear axle transmission crossbeam is a milestone in the use of polyamides in the chassis. It has the po- tential to set a new trend in the automo- tive industry,” says Kai Fruehauf, head of the ContiTech Vibration Control business unit. “In order to replace metal with high- performance plastics, it is necessary to make optimum use of the material and adapt it to the particular load situations, as BASF has demonstrated in the devel- opment of Ultramid for the transmission crossbeam.” BASF used its Ultrasim simulation tool in the early phase of development of the new crossbeam in order to determine the size of the component, optimise the component geometry and predict how the component would behave during injection moulding and in operation. The

sible to define the component geometry at an early stage and reduce the number of prototypes. BASF’s Performance Materials divi- sion encompasses the entire materials’ know-how of BASF regarding innova- tive, customised plastics under one roof. Globally active in four major industry sectors – transportation, construction, industrial applications and consumer goods – the division has a strong portfolio of products and services combined with a deep understanding of application-ori- ented system solutions. Strong capabili- ties in R&D provide the basis to develop innovative products and applications. q www.performance-materials.basf.com

Industry diary

August 2015 BELTCON 18 05-06 Aug

Birchwood Hotel and Conference Centre, Johannesburg, South Africa. Chris Townsend: IMHC organising committee +27 11 888 7163 or

+27 11 782 3595 ctr@beltcon.org.za www.beltcon.org.za

Index to advertisers Altair: Inspire solidThinking. .......... IBC Atlas Copco........................OFC, OBC Axiom Hydraulics............................ 2 BMG............................................ 33 Bonfiglioli.................................... IFC Set Point Group: Brubin Pumps....... 25 Festo............................................ 27 Hansen Industrial Gearboxes........... 14 Ingersoll Rand............................... 34 SAIW........................................... 16 SEW Eurodrive.............................. 18 SKF............................................. 29 SMC Pneumatics........................... 30 Tectra Automation......................... 24 Tega Industries.............................. 11 Voith Turbo................................... 10 Gas Africa Conference & Expo
 20-21 August, 2015

 Sandton Convention Centre, Sandston, Gauteng bettemc@mcnaughtonevents.co.za Bearings (2 Day) 17-18 Aug Secunda, Graceland Hotel Phindi Mbedzi:+27 11 325 0686 phindi@2kg.co.za www.2kg.co.za

simulation of ultimate loads, strengths under dynamic loading and crash safety was found to reflect the real com- ponent behaviour very well. ContiTech Vibration Control used Ultrasim’s

The new ContiTech transmission crossbeam for the rear axle of the

Mercedes-Benz S-Class is made from the lightweight engineering plastic Ultramid ® A3WG10 CR, a polyamide from BASF.

Integrative Simulation to model the entire manufacturing chain. Thus it was pos-

Certified Ultrasound Level 1 Training Martec: Johannesburg, September 2-4, 2015 The Level 1 Air borne and Structure Borne Ultrasound Inspector’s course is a compre- hensive two and a half day mix of theory and practical experience. Working from the Level 1 course guide, trainees are exposed to introductory sound theory and how it is ap- plied to the inspection disciplines demanded by an effective airborne and structure borne ultrasound inspection programme. The con- cepts and methods are demonstrated and reinforced by hands-on experiential exercises throughout the course.

Key benefit include: Improved equipment reliability; the prevention of unplanned out- ages; reduced maintenance costs, extended equipment life, improved maintenance effectiveness and the maximisation of main- tenance resources. In addition, ultrasound technology can help industrial users to save on energy, including electricity, and to im- prove their manufacturing efficiency. For a registration form or more information contact Margie Roes: Fax: +27 86 502 0634 or email: margie.roes@martec.co.za

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Mechanical Technology — July 2015