Innovative Engineering Solutions
www.sapparts.com Technology Brochure - 2013
MoS2 Coated Bushing: The significant property of MoS2, to form a hard to remove self lubricating layer @ 0.010 to-0.020mm over the surface allows the bush to bear the static and dynamic loads under a wide range, this results in reduced w e a r o f t h e m a t i n g s h a f t s a n d increased life of the bushing per application.
Technical Specifications:
Bench-marking Test Conditions:
Mating Shaft Requirements :
?Material - SAE-52100/20MnCr5/En-19 A ?Heat Treatment - Through Hardening / Case Carburizing
/Carbo Nitrating.?Surfcace Coating - Molybdenum Di Sulphide (MoS2)
?Max. Load - 500-900 Kgf/Cm2?Operating Speed - 30-60 M/min ?Greasing Frequency - Monthly Volume of Grease 1/3 of free volume.?Stopping Criteria - Un-due Noise/Discoloration of Contact Area.?Coefficient of Friction - Max 0.3 ?Contact pressure - 2700N/mm2 ?Dimensions & Tolerances - +/- 10 uM( Up to 50mm) +/- 20 uM( 150 mm) ?Roughness - 1.5 Rt ?Surface Appraisals - Fine tempered martensite.
?Material - En8,C-45,En-19A ?Hardness - 58-60 Hrc ?Treatment Done - Induction Hardening. ?Temp. of mating Pins - 40°C to 120 °C ?Applications - Link joint Bushes of Loader Arm, Front Axle.
BUSHINGS :Textured,Grooved & Surface Treated
Advantages :Life - more than 50 % life can be achieved as tested under standard test conditions as compared to the hardened alloy steel bushings.
Suitable for applications . · Front axle Assemblies of Tractors. · Link-joints of loader arms.· Joints bearing radial loads.
How customer will be benefitted :Benefits over normal hardened steel bushes, the significant property of MoS2 to form a hard to remove self lubricating layer @ 0.010 to-0.020mm over the surface allows the bush to bear the static and dynamic loads under a wide range ,this results in reduced wear of the mating shafts and increased life of the bushing. The cost benefit is always there by increased life per application.
Specially Textured Oil Grooves :
Open ended and closed Ended Loops carved inside the bore of bushings provide path for lubricating Oil and grease ensures the appropriate lubrication in between mating parts and improves service life of the bush. These bushings are also provided the antifriction graphite based Compound Molybdenum di sulphide.
L
-0.3-0.5
5.00
2-C1
C1
A A B B
A
2.40
15°
Ø54.9
5~55.0
Ø45.3
9~45.4
5
R1.0
0.8
0.8
0.8B
'Y'
'Y'
3.2-S
0.5~1.5x45°CH. BOTH ENDS.
1.50(TYP)
MoS2 Coting Layer
Durability Test of Bush in Machines
PRODUCTS:
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Duo Cone Seals - Innovative Technology
PRODUCTS:
PRODUCT VARIETY
SAP Parts comes in a wide range ( More Than 250 types) of products comprising of both, Alloy Forged Steel & High Chrome-Moly Alloy Castings , developed for specific OEM designated applications and numerous customized Duo Cone Seal for Special Applications.
BRAND PROMISE
SAP Parts is a Promising BRAND for Sustainable Quality with continuous improvements in all its Products, winning the confidence of customers across the Globe for the Best in Class Service and support at competitive prices.
INNOVATION
SAP through it expertise, is Capable to address the bizarre needs of customer providing innovative solutions at affordable cost that can replace conventional sealing methods & arrangements, deploying specialty Duo Cone Seals and assemblies.
TESTING & VALIDATION
Product Life - More than 200 % of conventional Duo cone Seals is warranted by SAP Parts, for they undergo an Unique & Next Generation life testing and Validation Methodology developed and applied by SAP Parts, for all the Products.
Part No:
S r. TEST C ycle
Descrip tio n Test C ycle in Hrs
Leak
age
Con
tact
Wid
th
Elas
tom
eter
Har
dnes
s
Dirt
Entr
yin
Oil
1 O il Leakage Test 100 HRS ü
2 Sea l C ontact Test 100 HRS ü ü
3 Hig h Tem p Test 300 HRS ü ü ü
4 Face Load Test 100 HRS ü ü ü ü
5 M ud Test 1000 HRS ü ü ü ü
6 Dust Test 1000 HRS ü ü ü ü
D UO C O NE SEAL TEST PLAN
Test Ind icators
2013
C ustom er Nam e:
Quality Material Conformance
Selection of alloy steel and cast material of high performance and excellent tribological properties, having fine inclusions of graphite, in the micro structure, allows higher sliding speed and reduced frictional losses.
Quality Material Conformance
Technology Brochure - 2013
ED
NN
F
EN
SA
L
IME
SIO
RE
RE
CE
Ø111.7
SD
ET
AIL
DIM
EN
SIO
N O
FH
OU
ING
3.0
0
±0.1
14
.5
17
.00
3.2
0
Ø104.0±0.1
32.0
0
R3
.00
10
°
R1.0
R0.5
R0.5
PRODUCTS:
REPORT NO/SAP/SLTR/005
DATE 14.10.2011
ACCELERATED ENDURANCE TEST FOR -
1] DETERMINATION OF SEAL LIFE
2] OIL LEAKAGE
SEAL LIFE AND LEAKAGE TEST RIG SYSTEM - SET UP CONDITIONS
OD mm 82.50 ID mm 63.50
9.50 m m
3.00 m m
2.00 Kg/cm 2
7.63 Kgf
Tim e
dd/m m /yyyy-
hh:m m
Hrs Linear
Speed in
M/
RPM SET Eqipm ent
Indicated
Face L oad
Kgf
Indicated
Tem p 0C
Band W idth
'S'
in m m
Start 29/0 7/2 011 6:0 0
31/0 8/2 011 0:0 0
31/0 8/2 011 6:0 0
13/0 9/2 011 0:0 0
13/0 9/2 011 0:0 0
Stop 02/1 0/2 011 16:0 0
TEST PERIOD 1000 % W ear 33.3%
7.63 Kgf
5.34 Kgf
5.10 mm
MAX.FACE LOAD150bC M AX
510
* TEST CONDUCT- SCHEDULE SEE OVERLEAF
6.8 100
In
Kantolom200 2.2 510
5 Kg/cm2
Normal
Condition500 2.2
HEATER TEM P.
TEST SAMPLE RANGE
FACE W IDTHMAX.M OTOR SPEED
LINEAR SPEED RANGE
MAX.LOAD
Endurance & L eakage
TEST
THRU ST LOAD GIVEN
LAP BAND W IDTH
4000 RPM
(0 ~ 7 3 ) M /s
OBSERVATIONS
CUSTOMER NAME :
SAP : TEST RIG SYSTEM FOR DUO CONE SEAL OIL LEAKAGE & LIFE ESTIMATION
DUO CONE SEA L # SAP-82.5 x 63.5 x16
XXXXXXXXXXXXX
7
7.2
4.5
DUO CONE SEAL LIFE TEST REPORT
Normal
Condition300 2.2 510
SAMPLE REF /DRG NO.TEST METHOD:
TEST MACHINE:
b(50 ~ 3 50 M M)
REMARK
TEST MACHINE PARAMETERS TEST SAMPLE PARAMETERS
ACCEPTANCE CRITERIA
LEAKAGE
MAX.FACE LOAD
* TEST
INTERVALS
18 HRS/DAY
7.2
-100
NO O IL L EAKAGE
SEAL FACE VISUAL NO BURNING/NO P ITTING
6.8
4.5
OK
No Le akage Found
MIN.FACE LOAD
MAX.BAND W IDTH
Sea l ha s qua l i fied the endura nce tes t a nd
lea ka ge tes t l imi ted for the s ta nda rd tes t
condi ti ons a s a bove a nd s hown no
s igni fi ca nt devia ti on i n a ccepta nce
cri tera under tria l of 1 000 hrs .
ABSTRACT OF RECORD SETTINGS REA DINGS
100 3.00
TEST RIG & SAMPLE ARRANGEM ENT
PARAM ETERS DESCRIPTION SPECIFICATIONS
SAE 52100 /100Cr6
Alloy Steel
Hardness
Through Hardened and
Tempered in controlled
atmosphere. Fine tempered
M arten site M icrostructure
60-63 HRc
Within 3 light Bands of Optical
interference
Flatness Attained By Diamond
Lapping
Process
Conforming to OEM
Specifications. Specially
Designed Ramp angle
Profile with Higher Grip
texture,to hold the O rings
firmly.
Operating Speed With Oil 10 M eter/Sec M ax
Operating Speed With Grease 3 M eter/Sec M ax
Pressure / Load Bearing
Capacity 3 Bars M ax
The Dual cone angle
range 8-15-20 Degree
Material Forged by Ring Rolling Process
The Flatness guarantee
on the surface 1~3 M icron M ax
The surface roughness
on the Lapped surface < 0.5Rt
Precision Manufacturing Technology H e a v y D u t y S e a l s a r e manufactured in the state of t h e a r t f a c i l i t y, i n v o l v e s F o r g i n g , C a s t i n g , H e a t treatment, Precision Lapping, Diamond Polishing processes.
DUO CONE SEALS :
Duo Cone Seal Features :
?Corrosion Resistant.?Precision lapped Rings.?Wear Re-countering Design.?Minimum face load variations.?Special Seal and O - ring materials.?Long Life - Warranted.?Self-renewing sealing surfaces.?Heavy Duty Applications.
Quality Assurance Facilities : ?Speciality Quality Instrumentation.?Surface Roughness Testing.?Hardness Testing.?Microscopic Image Analyzing.?Surface Finish Testing.?Seal Flatness Testing.?Oil Leakage Testing .?Endurance Testing & Validation.?Accelerated Seal life Test Rig.?Seal Face Load estimation M/c.
Technical Specifications:
Precision Engineered, High Quality & Heavy Duty Seals
www.sapparts.com Technology Brochure - 2013
www.sapparts.com
Globally Serves OEMs.
Customized Solutions.
Value Engineering.
Improved Design.
Life Tested.
Quality Material.
Precision Engineered Parts ForHeavy Duty Applications
Technology Brochure - 2013
Ahmadabad
Pune
Manufacturing Units
Works: SAP PARTS,Plot No.85, B.U.Bhandari Indl.Estate,Off Nagar Road, Near John Deere,Sanaswadi , Dist.PUNE - 412208.Maharashtra State - INDIAPh: 02137-619269,619271
Email: [email protected]
Note - All trade names, images, logos and machines displayed in this brochure, are representative and belong to respective company.
www.sapparts.comwww.sapparts.com
T VU
ISO 9001:2008ISO 9001:2008
Globally OEMs Served
Superior Quality.
Improved Design.
Life Assured.
Value Engineering.
Customized Solutions.
Technology Brochure - 2013