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: sap.parts@gmail.com

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