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    Collapsible Spacer Tube

    Uploaded by

    Mohamed Haris
    Tube Products of India is gearing up to supply collapsible spacer tubes to meet growing demand. Recent testing found compressive loads higher than specifications. Trials were conducted to address this including adjusting annealing temperature, speed, and testing mechanical properties. Simulation and testing showed the new process meets requirements with load vs deflection curves within specifications without an inner mandrel. This optimization aims to improve quality for customers.

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    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd

    Collapsible Spacer Tube

    Uploaded by

    Mohamed Haris
    132 views12 pages
    Tube Products of India is gearing up to supply collapsible spacer tubes to meet growing demand. Recent testing found compressive loads higher than specifications. Trials were conducted to address this including adjusting annealing temperature, speed, and testing mechanical properties. Simulation and testing showed the new process meets requirements with load vs deflection curves within specifications without an inner mandrel. This optimization aims to improve quality for customers.

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    Collapsible spacer tube

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    Tube Products of India is gearing up to supply collapsible spacer tubes to meet growing demand. Recent testing found compressive loads higher than specifications. Trials were conducted to address this including adjusting annealing temperature, speed, and testing mechanical properties. Simulation and testing showed the new process meets requirements with load vs deflection curves within specifications without an inner mandrel. This optimization aims to improve quality for customers.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    132 views12 pages

    Collapsible Spacer Tube

    Uploaded by

    Mohamed Haris
    Tube Products of India is gearing up to supply collapsible spacer tubes to meet growing demand. Recent testing found compressive loads higher than specifications. Trials were conducted to address this including adjusting annealing temperature, speed, and testing mechanical properties. Simulation and testing showed the new process meets requirements with load vs deflection curves within specifications without an inner mandrel. This optimization aims to improve quality for customers.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 12

    Tube Products of India

    Gearing for
    Growth

    ID30.6 X 2.3 X 36mm -Spicer Collapsible Spacer tube

    1
    Tube Products Of India – Avadi Plant – Chennai
    1.Introduction

    • Collapsible spacer is placed between pinion bearing used in differential


    • Collapsible Spacer tube used to obtain the specified amount of pressure or preload, plays the
    key role in transmitting load in Drive transmission

    TPI to ensure the below functional requirement


    1. HSLA Steel preferred for Good weld ability & formability
    *Recent lot issue – Compressive Load
    2. Dimensions , High %EL , YS/UTS ratio
    3. Should maintain Load absorption vs. Deflection value found to be higher than spec of
    86KN max during customer end testing
    & Internal Testing
    2
    Tube Products Of India – Avadi Plant – Chennai
    2.Past Supplied Records

    30.60X2.30X31.76 COLLAPSIBLE SPACER (Y1 MODLE)


    HOLLOW DETAILS Chemistry MTR LOAD V/S
    DEFELECTION

    CA MN PH SI SL AL UTS YS EL
    COIL LENGT 0.25 0.76
    DATE SHIFT R.C.NO OD THICK
    NO H 390 320
    0.065 1.00 0.01 0.10 0.008 0.04 34% 31000 / 59700 /
    mpa mpa
    max max max max max max min 86400 86400
    min min

    20-11- B219B0 JS19622


    C 63.5 3.5 4590 0.065 0.91 0.018 0.02 0.003 0.045 399.63 339.68 62 12199.7 63927.7
    2019 612 1

    05-Feb- B22020 JS19738


    C 63.5 3.2 5000 0.071 0.9 0.018 0.032 0.003 0.043 395.32 336.54 62 14187.5 71388
    20 077 4

    24-Sep- B22090 JS20979


    C 63.5 2.95 5270 0.073 0.89 0.013 0.016 0.005 0.045 396.06 325.97 60    
    20 958 4

    10-Nov- B220B0 JS20979 41992.0 105786.


    C 63.5 2.95 5270 0.073 0.89 0.013 0.016 0.005 0.045 390.31 329.81 62
    20 574 4 5 83

    10-Dec- B220C0 JS20979


    B 63.5 2.95 5270 0.073 0.89 0.013 0.016 0.005 0.045      
    20 339 4
       

    * 3.2 & 3.5mm Input thickness used in previous lots

    3
    Tube Products Of India – Avadi Plant – Chennai
    3. Part 2D Drawing

    4
    Tube Products Of India – Avadi Plant – Chennai
    4. Tensile Properties

    Tensile Data
    450

    S. 0.2% 400
    No YS(Mpa UTS(Mpa) %EL YS/UTS
    )
    350

    300

    Stress [MPa]
    250
    1 312 392 54.29 0.79
    200

    150

    2 313 393 53.83 0.79 100

    50

    0
    3 307 391 53.78 0.78 -10 0 10 20 30 40 50 60

    Strain [%]

    Note: recent lot tubes were tested at CTC to understand any variation in YS,UTS &
    %EL

    5
    Tube Products Of India – Avadi Plant – Chennai
    5.LS Dyna Simulation ( without ID mandrel)

    36mm length compressed to 31mm with compressive load of 60KN for forming & 40kN
    required for 0.25mm deflection

    6
    Tube Products Of India – Avadi Plant – Chennai
    5.Load Vs Deflection ( Without ID mandrel)

    Load vs Deflection curve plotted which is meeting customer requirement without using
    ID mandrel during forming ( but in actual ID mandrel has been used)

    7
    Tube Products Of India – Avadi Plant – Chennai
    Trial Feedback

    8
    Tube Products Of India – Avadi Plant – Chennai
    1.Muffle Furnace Trial

    Heating &
    S.no Temperature Soaking Cooling rate YS(MPa) UTS(MPa) %EL

    10 &
    1 900deg C 15mins 271 354 52
    15deg/min

    Note:
    1. Furnace Heating rate -20deg/min, Soaking – Per Wall thickness/5mins & Cooling rate –
    15mins per min

    9
    Tube Products Of India – Avadi Plant – Chennai
    2. Trial Summary
    Load (N) vs
    Annealing Annealing Deflection(mm)
    IP Bulge FG
    Condition Furnace Temperatur Speed YS(Mpa) UTS(Mpa) %EL Length(mm) Dia(mm) Area(mm2)
    e 0.25mm 0.75mm

    36 38 268.99 26606 100202


    Existing 36 38 268.99 30103 101079
    RH 680°C 30IPM 329 390 52
    Process 38 39 283.93 30422 97622
    38 39 283.93 36373 97823
    37 38 276.46 35742 104439
    37 38 276.46 43321 104761
    38 39 283.93 39484 102114
    Trial 1 RH 680°C 27IPM 313 392 54
    38 39 283.93 41232 103255
    39 40 291.40 35509 97747
    39 40 291.40 39121 99819
    34 254.04 32333 101532
    34 254.04 36115 102488
    35 261.51 32981 101006
    35 Not 261.51 34286 101649
    32( tested 38 measured 283.93 29684 95270
    Trial 2 RH 900°C 30IPM 310 388
    at ctc) 38 283.93 32039 99220
    39 291.40 33392 98068
    39 291.40 37122 98454
    40 44 298.87 29338 94184
    40 44 298.87 35334 95308
    36 38 268.99 42010 91940
    36 38 268.99 42673 95414
    Trial 3 Muffle 900°C 15mins 271 354 52
    Furnace Soaking 38 39 283.93 36291 91856
    40
    Tube collapsed
    41

    Note:%EL varies between CTC & IBP lab to be ignored

    10
    Tube Products Of India – Avadi Plant – Chennai
    3.Tube Collapsed Image

    Tubes collapsed during trial carried out with IP length – 41mm to achieve
    higher Area in 900 deg /15mins muffle furnace soaked tube

    11
    Tube Products Of India – Avadi Plant – Chennai
    4. Way forward
    • From the trial Summary table, It is evident that the area increases , Load has been
    decreased gradually
    • Annealing temperature & Soaking time increases , Both Tensile & Compressive load
    decreases
    • When we carried out both combination of 900 deg annealing with increased area, tubes
    collapsed due to limitation of mechanical crank press
    • ID mandrel needs to be modified accordingly or collapsible spacer tube to formed through
    hydraulic load controlled press ( may affect productivity)

    12
    Tube Products Of India – Avadi Plant – Chennai

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