Mechanical Technology

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40 Mechanical Technology — July 2015
⎪ Nota bene ⎪
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
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
Bearings (2 Day)
17-18 Aug
Secunda, Graceland Hotel
Phindi Mbedzi:+27 11 325 0686
Gas Africa Conference & Expo
20-21 August, 2015
Sandton Convention Centre,
Sandston, Gauteng
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
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
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:
World’s first plastic rear axle transmission crossbeam
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.
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