Future chassis strategies are based on a few high-volume platforms that are used for a wide range of vehicle models with kinematic variants and different axle loads. TRW Linkage & Suspension (now business unit of THK Rhythm Automotive) has developed an economical production technology that makes modular mass production of cost- and weight-effective suspension components made from stamped steel possible. The crimped stamped steel ball joints are going into mass production in 2017.
REDUCTION OF PRODUCTION STEPS
The kinematic requirements for suspension components in vehicle chassis systems, for example deflecting, turning and guiding the wheels, are realised using ball joints that are fitted to the knuckle using control arms or tie rods. The ball joints usually consist of a steel ball pin that is mounted in a greased plastic socket, which in turn is mounted in a housing and sealed with a plug and a rolled edge. The ball joint is protected from moisture and dirt particles by a rubber boot at the ball pin side.
Machined hot forged housings made from steel or aluminium are typically used. The functional characteristics of the ball joints, for example movement torques, stiffness and wear behaviour, require precision machining of the inner housing geometry, since a defined contact pressing between the ball, the plastic socket and the housing has to be achieved. Galvanised surface protection is applied to the forged steel housings after machining, which is carried out by the suppliers. This results in additional logistical effort and feeding of the housing into the ball joint assembly process.
These complicated production steps and the objective of continuous production were the motivation for developing a crimped stamped steel housing for light vehicle ball joints that saved money and reduced the weight in comparison to the forged housing with the same performance. The development was carried out from 2010 to 2013 by the TRW Automotive Linkage & Suspension division. The Japanese THK Rhythm group took over the division in August 2015, and is continuing with the product ranges.
MODULAR SYSTEM OF CRIMPED STAMPED STEEL HOUSINGS
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