Name : Flange/Muff cups
Model: Bajaj Re
Quality: A plus
Material: Alloy steel
Delivery: 30 days
Guarantee: 3 months
Material and processing of drive shaft flanges
Bajaj Re drive flange is an important component connecting the Axle and the wheel or differential. It needs to withstand torque, bending and impact loads, so it has high requirements for materials and processing technology.
1. Common materials
Medium carbon steel (such as 45 steel)
Features: Carbon content is about 0.45%, strength and toughness are balanced, low cost, easy to process and heat treat.
Application: Medium and low load passenger car or commercial vehicle half-axle flange.
Heat treatment: Quenching and tempering treatment (quenching + high temperature tempering), hardness reaches 25-35 HRC.
Alloy steel ( 40Cr, 42CrMo)
Features: giving elements such as Cr and Mo to improve hardness, strength and wear resistance.
Application: Heavy duty trucks
Heat treatment: Surface high-frequency quenching after quenching and tempering, hardness can reach 50-55 HRC.
Stainless steel ,like SS304 and SS316
Features: Strong corrosion resistance, but high cost, and lower strength than alloy steel.
Application: Special environments (such as marine or chemical vehicles).
Forged aluminum alloy (6061-T6)
Features: Lightweight, but low strength, requires strengthening design.
Application: New energy vehicles or models with high weight reduction requirements.
2. Processing process
1. Forging process (mainstream method)
Steps:
Cutting: Sawing or shearing bars.
Heating: To forging temperature (about 1200°C for steel).
Die forging: Press forming, grain refinement, and strength improvement.
Trimming: Remove burrs.
Heat treatment: Tempering or surface hardening.
Advantages: Continuous fiber streamlines, better mechanical properties than casting.
2. Casting process (low-cost solution)
Applicable: Low load or complex structure.
Process: sand casting/precision casting, heat treatment is required to eliminate internal stress.
Disadvantages: easy to produce pores, shrinkage, low strength.
3. Machining
Turning: CNC lathe processing flange end face, bolt hole, journal, etc.
Drilling/tapping: Processing mounting holes, the accuracy must reach IT7 level.
Grinding: High-precision mating surfaces need to be ground (Ra≤1.6μm).
4. Surface treatment
Rust prevention: electrogalvanizing, phosphating or Dacromet coating.
Wear resistance: high-frequency quenching or carburizing treatment (only for local areas).
III. Key process control points
Heat treatment consistency: avoid deformation or uneven hardness.
Bolt hole position: ensure the centering with the wheel hub or differential (tolerance ±0.05mm).
Dynamic balance test: high-speed rotating parts need to control the imbalance (such as ≤15g·cm).
4. Development Trends
Lightweight: Use high-strength steel or aluminum alloy, combined with topological optimization design.
Integrated manufacturing: 3D printing (such as titanium alloy) for customized flanges.
Green process: environmentally friendly technologies such as low-temperature forging and cyanide-free galvanizing.
Summary
Material selection: medium carbon steel (economical), alloy steel (heavy load), aluminum alloy (lightweight).
Process core: forging + heat treatment + precision machining, taking into account both strength and precision.
Quality control: Strict testing of hardness, dimensional tolerance and fatigue life (such as bench testing) is required.
The material and process combination can be flexibly adjusted according to the load, cost and weather resistance requirements of the specific vehicle model.
Common problems and cause analysis of Bajaj and Tvs king Flange
During long-term use, automobile flanges may fail due to design, material, processing or assembly problems, affecting the reliability and safety of the vehicle's transmission system. The following is a detailed summary of common problems, cause analysis and solutions
1. Common problems and cause analysis
1. Flange fracture
Phenomenon: Cracks or even complete fractures around the flange or bolt hole.
Cause:
Material defects: inclusions, forging pores or improper heat treatment (such as quenching cracks).
Overload: Fatigue fracture caused by overloaded transportation or intense driving.
Design problem: Too small transition radius leads to stress concentration.
Typical case: Radial cracks appear on the flange of a heavy truck half shaft under long-term bumpy road conditions.
2. Bolt loosening or fracture
Phenomenon: The fixing bolts are loose, stretched or sheared.
Cause:
Insufficient preload: Failure to tighten according to the standard torque (such as ignoring the anti-loosening gasket).
Insufficient bolt strength: Use low-grade bolts (such as 8.8 instead of the required 10.9).
Flange deformation: Flange flatness tolerance leads to uneven force.
3. Flange surface wear or corrosion
Phenomenon: Scratches, pits or rust appear on the contact surface.
Cause:
Poor lubrication: Grease contamination or dry friction of wheel hub bearing.
Material is not wear-resistant: No surface quenching (such as insufficient hardness of 45 steel).
Environmental corrosion: Stainless steel flange is not passivated in salt spray and acid rain environment.
4. Oil leakage from mating surface
Phenomenon: Gear oil leakage occurs at the contact point between flange and oil seal.
Cause:
Low machining accuracy: Insufficient journal roughness (Ra＞1.6μm) or excessive roundness.
Aging of oil seal: Hardening and cracking of rubber oil seal.
Axial movement: Bearing wear causes axial displacement of flange.
5. Dynamic balance failure
Phenomenon: Steering wheel shakes or body resonance when driving at high speed.
Cause:
Flange imbalance: Uneven weight distribution of cast/forged blank.
Eccentric installation: Too large clearance between flange and half shaft (such as keyway wear).
2. Solutions and preventive measures
1. Material and process optimization
Forging control: Use precision forging technology to avoid folding cracks; perform ultrasonic flaw detection on 42CrMo materials.
Heat treatment strengthening: Add induction quenching after quenching and tempering, and the depth of the hardened layer is ≥2mm (such as the gear ring part).
Anti-corrosion treatment: Carbon steel flange adopts "phosphating + electrophoresis" double-layer protection.
2. Assembly specifications
Bolt tightening: Use a torque wrench to tighten in three times (such as 30%→60%→100% final torque).
Match inspection: Measure the flange end runout before installation (should be ≤0.05mm).
3. Maintenance recommendations
Regular inspection: Check the torque and surface condition of the flange bolts every 20,000 kilometers.
Lubrication management: Use high-temperature lithium-based grease to lubricate the hub bearing to avoid grease contamination of the flange surface.
4. Design improvement
Stress optimization: Increase the transition radius (R≥5mm) through finite element analysis (FEA).
Lightweight design: The aluminum alloy flange adopts a reinforced rib structure to compensate for strength.
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