1、This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2009 by Navistar, Inc. OCTOBER 2009 Page 1 of 7 NAVISTAR, INC. TMS (TRUCK MATERIAL SPECIFICATION) NUMBER:
2、 TMS-1044 TITLE: Tapered Leaf and Air Ride Control Arm Suspension Springs CURRENT REV. No.: 0910 DATE: October 2009 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES: Rev. N - February 2006 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION Thi
3、s specification may involve hazardous materials, equipment, and procedures. This specification does not purport to address all of the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to determine the applicability of regulatory lim
4、its prior to use. Change Notice: Replaced “International Truck and Engine Corporation” with “Navistar, Inc.” per corporate directive; in Section 4.6 changed min grain size number for 5160 to 6; editorial changes. Reference: File 03-1 Keywords: Springs, tapered leaf springs, control arm springs, susp
5、ension springs. 1.0 APPLICATION This specification covers steel tapered leaf suspension springs and air ride control arm suspension springs. 2.0 SCOPE This specification covers requirements for material, dimensional tolerances, KCC, heat treatment, microstructure, post-hardening treatments, source a
6、pproval/quality control, shipping, and identification. 2.1 Restricted Chemical Substances Effective January 1, 2007, all product supplied to the requirements of this specification must comply with the requirements of the CEMS B-50 specification. 3.0 REFERENCE DOCUMENTS Unless otherwise specified the
7、 latest issue of all referenced standards shall apply. The following Specifications, Standards, and Regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 NAVISTAR TMS-4516 ASTM E 112 CFR Title 29, Part 1910 NAVISTAR CEMS GT-4D ASTM E 1382 NAVISTAR Engineering
8、 Design Std. A-16 NAVISTAR CEMS GT-5A SAE J400 NAVISTAR Manufacturing Std. MS-D-13 NAVISTAR CEMS GT-7D SAE J419 NAVISTAR CEMS A-0, Part I NAVISTAR CEMS GT-14C SAE J422 NAVISTAR CEMS A-0, Part III ASTM A 29 SAE J510 NAVISTAR CEMS A-39 NAVISTAR CEMS B-50 SAE J788 4.0 REQUIREMENTS 4.1 Material Open hea
9、rth, basic oxygen or electric furnace, ingot cast or strand cast, steel may be used. Unless otherwise specified, the general requirements for steel as described in ASTM A 29 shall be applicable. Steel supplied shall be fully killed, made to fine grain practice, and shall meet the minimum Steel Clean
10、liness Requirements for Quality Level I per CEMS A-0, Part I. Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-NUMBER: TMS-1044 TITLE: Tapered Leaf Springs & Air Ride Control Arm S
11、uspension Springs REVISION: 0910 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2009 by Navistar, Inc. OCTOBER 2009 Page 2 of 7 4.2 Chemical Composition
12、 TAPERED LEAF SPRINGS CONTROL ARM SPRINGS Carbon 0.66% max Carbon 0.60% max Silicon 0.35% max Silicon 0.30% max Phosphorus 0.040% max Phosphorus 0.025% max Sulfur 0.050% max Sulfur 0.035% max Alloy elements as required Alloy elements as required 4.3 Heat Treatment Springs shall be hardened and tempe
13、red at 425C (800F) minimum. 4.3.1 Tapered Leaf Springs: Brinell hardness shall be 401-444 HBW for 5160 (or equivalent) alloys, and 415-461 HBW for 6150 (or equivalent) alloys. The hardness shall be checked on the compression surface after grinding away any decarburization layer to assure accurate bu
14、lk material hardness. 4.3.2 Control Arm Springs: Brinell hardness shall be 415-461 HBW. The hardness shall be checked on the compression surface after grinding away any decarburization layer to assure accurate bulk material hardness. 4.4 Hardenability Steel shall be selected to meet the minimum hard
15、enability, based on the thickness of the hot rolled bar. Thickness Steel Code* mm in 9.8 and Under 0.386 and Under C47-66E6 (52)-22 (52) Over 9.8 Over 0.386 C47-66E8 (52)-32 (58) * Per Navistar CEMS A-0, Part III. See General Information for suggested steels. 4.5 Dimensional Tolerances 4.5.1 Thickne
16、ss and Width Shall be as specified in SAE J510, Leaf Springs for Motor Vehicle Suspension. In addition, SAE J788, Design and Application of Leaf Springs, shall govern areas not covered in J510, and shall supersede drawing tolerances where conflicts exist. 4.5.2 Loaded Height (Front Spring Only) Tape
17、red leaf spring assemblies used in front suspensions shall be sorted by the supplier to control loaded camber height at rated load condition specified on drawing. Springs shall be marked on the front side of the wrapper leaf of the front spring eye as per the table below. Number of Vertical Stripes
18、HEIGHT Tolerance, mm 1 -6.4 H -3.2 2 -3.2 H 0 3 0 H + 3.2 4 +3.2 H +6.4 Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-NUMBER: TMS-1044 TITLE: Tapered Leaf Springs & Air Ride Con
19、trol Arm Suspension Springs REVISION: 0910 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2009 by Navistar, Inc. OCTOBER 2009 Page 3 of 7 4.6 Microstruc
20、ture The microstructure shall consist of 90% min tempered martensite at the center of the heaviest section. The 5160 (or equivalent) steel shall be fine grained min grain size number 6 (grain size measurement as per ASTM E 112 or ASTM E 1382). The 6150 (or equivalent) steel, used for the control arm
21、s, shall be extra fine grained (min grain size number 8). Intergranular oxidation shall not exceed 0.05 mm (0.002 in). Depth of decarburization shall be controlled within the following limits: Leaf Size (Thickness) Decarburization* Thru 17.8 mm (0.70 in) 0.25 mm (0.010 in) max 18.0-27.7 mm (0.71-1.0
22、9 in) 0.30 mm (0.012 in) max Over 27.7 mm (1.09 in) 0.62 mm (0.020 in) max *Type 2 per SAE J419 max severity. 4.7 Spring Eye Bushings (Applicable to both rubber and threaded bushings) 4.7.1 Tapered Spring Eye Bushings The bushing push-out force is dependent upon the suspension rating. The bushing sh
23、all be bonded into the spring eye such that the bushing will withstand the minimum push-out force indicated in the table for that suspension rating, without any movement or loosening. SUSPENSION RATING, (LBS) LOAD AT GROUND (per side) (LBS) PUSH-OUT FORCE (MIN. LBS) 6 000 3 000 2 400 7 000 3 500 2 8
24、00 8 000 4 000 3 200 10 000 5 000 4 000 12 000 6 000 4 800 14 000 7 000 5 600 16 000 8 000 6 400 18 000 and above 9 000 + 7 200 *Unless otherwise indicated on the Engineering drawing or purchase order, the minimum push-out force for each suspension ratings is as indicated in the Table above, without
25、 movement or loosening. 4.7.2 Control Arm Spring Eye Bushings SUSPENSION AXLE RATING (LBS) WHEEL LOAD (LBS) PUSH-OUT FORCE (MIN. LBS) 12 000 6 000 4 800 13 500 6 750 5 400 15 500 7 750 6 200 17 000 8 500 6 800 17 500 8 750 7 000 19 000 9 500 7 200 19 800 9 900 7 200 20 000 10 000 7 200 21 000 10 000
26、 7 200 23 000 11 500 7 200 Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-NUMBER: TMS-1044 TITLE: Tapered Leaf Springs & Air Ride Control Arm Suspension Springs REVISION: 0910 Th
27、is document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2009 by Navistar, Inc. OCTOBER 2009 Page 4 of 7 *Unless otherwise indicated on the Engineering drawing or p
28、urchase order, the minimum push-out force for each suspension ratings is as indicated in the table above, without movement or loosening. 4.8 Post Hardening Treatments The tension surface of each leaf shall be stress peened per Class IND, 6-10C per CEMS A-39, except that the coverage shall be 100% mi
29、nimum. Each leaf shall be prestressed to 1170 MPa (170 000 psi) minimum during the peening operation. Expected minimum residual stresses are 755 MPa (110 000 psi) at the surface and 965 MPa (140 000 psi) at a depth of 0.1-0.25 mm (0.004-0.010 in) below the surface. 4.8.1 After stress peening, each l
30、eaf shall be coated/primed with an approved paint (Type IV per TMS-4516). Dry film properties will meet the requirements as indicated in the table below. Property Required Test Method* Thickness, min (see Note) 38m (1.5 mil) ASTM D 1186 or D 4138 Adhesion, min 90% GT-5A Hardness, min B GT-4D Gravelo
31、meter, min 80% Retained SAE J400 Cold Crack Pass GT-14C Salt Spray, 250 Hrs (creepage, max) 1.5 mm (0.06 in) GT-7D * Navistar CEMS Test Method unless otherwise indicated. NOTE: The dry film thickness for Zinky 101E may be 25m (1 mil) provided that all other dry film properties are met. 4.9 Endurance
32、 Test Requirements 4.9.1 Tapered Leaf Springs * Unless otherwise specified, assemblies shall exhibit a minimum B10 life of 100 000 cycles*, when tested as indicated. 4.9.1.1 Clamp assembly and cycle from +0.5 to +2.0 G G, minimum = rated load at the wheel (minus the unsprung weight) 4.9.1.2 For new
33、parts, 6 samples shall be tested for initial qualification. 4.9.1.3 For parts with prior production history, 3 samples shall be tested. 4.9.2 Control Arm Springs * Unless otherwise specified, assemblies shall exhibit a minimum B10 life of 110 000 cycles*, when tested as indicated. 4.9.2.1 Clamp asse
34、mbly and cycle from 0.25 to +2.25 G (G, minimum = rated load at the wheel (minus the unsprung weight) 4.9.2.2 For new parts, 6 samples shall be tested for initial qualification. 4.9.2.3 For parts with prior production history, 3 samples shall be tested. *Tests may be suspended after 250 000 cycles.
35、5.0 QUALITY Surface of the leaves shall exhibit no visual evidence of significant discontinuities such as laps, scale, scabs, and slivers, and shall exhibit no transverse tool marks or gouges. (Transverse is defined as being perpendicular to the Copyright Navistar International Corporation Provided
36、by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-NUMBER: TMS-1044 TITLE: Tapered Leaf Springs & Air Ride Control Arm Suspension Springs REVISION: 0910 This document is restricted and may not be sent outside Navistar, Inc. or reproduce
37、d without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2009 by Navistar, Inc. OCTOBER 2009 Page 5 of 7 length of the leaf within an angle of 15 from the perpendicular.) Surface discontinuities such as pits, longitudinal tool marks or gouges an
38、d other depressions are permissible provided they are not deeper than 0.25 mm (0.010 in) and that they do not have a sharp radius root radius to be less than 0.75 mm (0.030 in). Leaves shall also be free from pipe, bursts, and laminations. Maximum depth of seams shall be 0.02 mm (0.001 in) per 1.6 m
39、m (0.06 in) thickness (at the point of measurement). 5.1 KCC - Quality Control Plan A Quality Control Plan for this product will be established by mutual agreement between International and the supplier. The following five (5) characteristics, where applicable*, shall be included in the plan as feat
40、ures for management by statistical process control*. 1. Width at the leaf ends 2. Pack width at points 3.0 0.1 inch on either side of the spring center. 3. Center bolt height above the main leaf 4. Finished bushing ID or thread pitch diameter 5. Spring loaded height * Additional characteristics for
41、inclusion in the Control Plan may be specified on the engineering drawing or purchase order. * See Engineering Design Standard A-16. 6.0 SOURCE APPROVAL AND QUALITY CONTROL 6.1 Supplier Requirements All suppliers to NAVISTAR are required to be registered to ISO 9001 Quality System Requirements. NAVI
42、STAR will also accept TS-16949 registration as long as the supplier can also fulfill all AIAG PPAP (Production Part Approval Process) documentation and approval requirements. Suppliers must maintain their certification with an accredited registrar and must furnish copies of registration certificates
43、 to their Corporate Buyer upon request. 6.2 Approval Parts supplied against contracts or purchase orders citing this specification shall be equivalent in all respects to those samples that were approved by the purchaser. No changes in formulation or processing practices are permitted without approva
44、l. In the event that changes in material, properties, processing practices, construction, color, or labeling of the product are required, the supplier shall notify Truck Development and Technology Center and Purchasing and Supplier Development of the proposed change(s). Test data indicating conforma
45、nce to all requirements of this specification, test samples, and new or amended or updated Material Safety Data Sheets (MSDS), in accordance with CFR Title 29, Part 1910, shall be submitted with the request for change. 6.3 Process Control The supplier shall either perform and report results of tests
46、 on specific lots of parts produced using ISO 9001 or TS-16949 guidelines, or provide statistical evidence of the lot having been produced in a state of statistical control and with a process capable of providing all required properties. The part supplier and the plant metallurgist and/or the qualit
47、y control manager of the using NAVISTAR plant may determine testing and reporting requirements on specific products. Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-NUMBER: TMS-10
48、44 TITLE: Tapered Leaf Springs & Air Ride Control Arm Suspension Springs REVISION: 0910 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2009 by Navistar,
49、 Inc. OCTOBER 2009 Page 6 of 7 6.4 Approved Material Suppliers 6.4.1 Steel Steel for Control Arm Springs will be provided by ISPAT Sidbec. Steel supplied will have a minimum reduction ratio of 6:1 and a chemical composition and production practice capable of providing the required fine grain size and with suffi
