Realistic simulation and tailored coatings for optimal, efficient product development

2014-09-23 | 000-005-313 DE-EN

SCHAEFFLER AG, BERLIN/SCHWEINFURT

360 Lifecycle Management - Schaeffler at InnoTrans 2014

Realistic simulation and tailored coatings for optimal, efficient product development

For propelled freight cars and passenger cars or for traction vehicles - with more than 100 years of experience in railway engineering, Schaeffler can find the ideal system solution for any application. Along with products with optimized friction and performance characteristics, modern calculation and simulation tools are becoming key to increasing the efficiency of roller bearings. Product and system development tools drastically cut development costs and times.

Roller bearing analysis using BEARINX and CABA3D

FE calculations are performed in the design and modeling phase to verify the strength of housings and conversion parts using, among other programs, BEARINX , a roller bearing calculation program developed by Schaeffler, and the CABA3D simulation program for detailed analysis of complex dynamic processes occurring in the bearing and for load-adapted bearing design. BEARINX has undergone continuous improvement for more than 15 years and combines traditional and modern engineering knowledge with innovative analysis possibilities in a complete calculation system for the design and dimensioning of roller bearings. The program's outstanding performance, combined with the specialist knowledge of Schaeffler's application engineers and customers' practical experiences, generate innovative and technically sophisticated solutions.

Coatings to meet any demands

To protect rail bearings against passage of current, corrosion, fretting corrosion, wear, friction, or slippage according to the given application, development engineers at Schaeffler's Surface Technology Competence Center have the equipment and capacities required to come up with innovative solutions, especially through combining different coating methods and materials. The rapid implementation of tailored, customer-oriented surface solutions is always at the fore.

For corrosion protection, the Corrotect ZI (zinc-iron alloy) and Corrotect ZN (zinc-nickel alloy) coatings are the right choices. Corrotect ZN has been shown to exhibit exceptional protection against red rust formation for up to 720 hours in salt spray tests in accordance with DIN EN ISO 9227.

The Durotect coating is used to prevent premature wear of rolling elements in traction motor bearings and axlebox bearings and to reduce friction. For example, Durotect B (mixed iron oxide coating) improves the running-in behavior of bearings and supports deep groove ball bearings in traction motors under poor lubrication conditions. Durotect Z (zinc phosphate coating) is often used as anti-corrosion protection for axlebox bearings. It reduces fretting corrosion in the bearing seats and friction in the sliding fit. Further variants include Durotect M (manganese phosphate coating) for improved sliding and running-in behavior and Durotect NP (nickel-phosphorous coating) for anti-wear and anti-corrosion protection.

With its Insutect A insulation coating or, alternatively, with the use of ceramic rolling elements, Schaeffler offers two effective tools for rolling bearing damage caused by electrical current.

Accredited testing facilities for railway axlebox bearings

The axlebox bearings used here are subjected to extreme loads at the connecting point of the wheelset and the bogie frame. To improve safety during daily operation and to minimize wear as well as maintenance requirements, Schaeffler operates accredited testing facilities in which the performance capabilities of axlebox bearings for railway applications can be evaluated.

Schaeffler has had decades of experience in the testing of axlebox bearings. The first tests were conducted in Schweinfurt about 50 years ago. The company's testing center in Germany has been accredited for eight years now, and its first axlebox bearing testing facility in China was set up five years ago.

All test stands enable performance tests according to the requirements specified in the European standard EN 12082. Functional tests conducted according to this standard prove that the axlebox bearings are suitable for use in real driving conditions. The additional expansion of capacities in both countries means that a shorter period of time is required for bearings to be approved. Customers and end users alike profit from the reduction in lead times for the verification tests needed for vehicle approval.

Close cooperation with customers for individual solutions

The Schaeffler applications technology team advises customers in selecting from a range of high-caliber products and assists with questions regarding design of bearing environments, lubrication, and sealing as well as bearing installation and removal. The close cooperation with domestic and foreign universities, research institutions, and trade associations facilitates exchange of the latest research results, which is crucial for development work.

The close cooperation between the Industrial and Automotive divisions within the Schaeffler Group allows innovations and expertise from the fields of materials technology, mechatronics, and sensor technology to be adapted to applications in the railway sector. Areas of development focus include innovative new developments in tribology and seal technology.

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