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Mercedes-Benz

Date Published: 2008-07 Total No. of Pages: 12 Department: PWT/VWK Person in Charge: Stefan Schlayer Tel.: +49(0)7031 90-44275 Person in Charge: Thomas Zehnder Phone: +49-(0)711 17-39150

DBL 6218

Supply Specification
Elastomer mounts, isolators and bushings

Foreword
DBL 6218 describes the supply specifications for elastomer mounts, isolators and bushings. The individual points and requirements shall be fulfilled in line with the Mercedes development process (MDS). The supplier is entitled to present alternative solutions. Such solutions shall allow the target to be reached with the same degree of fulfillment and shall be agreed with Daimler AG. Process ownership, product liability and warranty shall remain with the supplier. The supplier shall ensure that these requirements are known to any sub-suppliers and are complied with. Suppliers bear overall responsibility towards Daimler AG. In principle, this Standard does not claim to be complete. In the interest of continuous process optimization, the procedures and requirements shall always be adapted to the state of the art. The latest version of this document is available through the standards information systems of Daimler AG.

Changes
The following changes were made as against DBL 6218 edition 2002-11: Editorial revision Revision of Foreword Amendment and revision of Sections: 2.1.4; 2.1.9; 2.3.2; 2.3.9; 2.3.6 AK Requirement Specifications LH 10 "Index e updated to "Index f Product version 11 for elastomer-mounted absorbers added

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Contents
1 2 3 Application .......................................................................................................................................................... 2 Part 1: Development, process planning, production ......................................................................................... 3 Part 2 : General conditions, versions, test methods......................................................................................... 12

Application
Application examples Annex to AKRequirement Specifications 10 Annex 01 Annex 02 Annex 03 Annex 04 Annex 05 Annex 06 Annex 07 Annex 08 Annex 09 Annex 10

Product version (PV) 01 02 03 04 05 06 07 08 09 10 11

Spring isolators/Shock mounts Tension/Compression control arm bushings Subframe bushings Control arm bushings Control arm bushings (rear axle) Track link bushings (rear axle) Differential mounts (rear axle) Drivetrain isolators (with comfort function) Drivetrain isolators (with guide/support function) Elastomer mounts, isolators and bushings, other applications Elastomer-mounted absorbers

Abbreviated designation: For drawings in the block for material: e.g. Composite material DBL 6218.07.

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2
2.1

Part 1: Development, process planning, production


Component development
Responsible DAIMLER AG DAIMLER AG

2.1.1 Creation of component requirement specifications 2.1.2 Definition of suitable quality characteristics for component description (characteristic curve, characteristic frequency, damping, geometry, press-in force). All quality characteristics shall be toleranced 2.1.3 Definition of endurance test, stress, number of load changes (DBL 6218), determination of stress and strain spectrum (static-dynamic mechanical, temperature, media) 2.1.4 Analysis of environment and definition of any corrosion requirements for components 2.1.5 Finite element design of the component with material data under the influence of temperature, determination of most highly stressed zone 2.1.6 Selection of elastomer material, temperature, exposure to substances, dispersion, stress, DBL approval 2.1.7 Consideration of environmental/legal requirements (ELV directive, Negative substance list for the selection of materials) 2.1.8 Filling pattern simulation, no confluence of flow fronts in the most highly stressed zone, filling time study, scorch Index taken into account 2.1.9 Definition of traceability requirements, definition of batch

DAIMLER AG DAIMLER AG Supplier Supplier, Daimler AG Supplier Supplier DAIMLER AG

2.2

Process development
Responsible Supplier Supplier Supplier Supplier Supplier Supplier, Daimler AG Supplier, Daimler AG Supplier, Daimler AG DAIMLER AG

2.2.1 Planning and specification of mixing process, mixing plant 2.2.2 Planning and specification of vulcanization method, machine concept (automation, reworking) 2.2.3 Planning and specification of engineering of vulcanization molds (runner technology, temperature, pressure, spatial and temporal volume distribution) 2.2.4 Planning and specification of pre-treatment process 2.2.5 Planning and determination of manufacturing locations; these shall be notified to Daimler AG 2.2.6 Definition of appropriate characteristics and tolerances (derived from process FMEA) for process assurance of other raw materials and semi-finished products (metal part pretreatment) 2.2.7 Definition of appropriate quality characteristics and tolerances for the vulcanization process assurance (fracture pattern, adhesion, press-out force) 2.2.8 Endurance test, fulfillment of component requirements on trial parts. In case of deviating test conditions, evidence of the correlation of the test methods and results shall be provided; the deviating methods shall be discussed with DAIMLER AG 2.2.9 Early audit (e.g. VDA 6.3 elements M1-3) by EP, QM and PWT. QM units shall verify planning and execution of capability certifications (Quality Gate C_B)

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2.3

Production process planning


Responsible

2.3.1 Transfer of quality characteristics to intended production process 2.3.2 Capability studies: capability studies shall be performed with regard to product, production facilities and process. Determination of effects of process parameter changes on quality characteristics (ranges for action limits, limit values) 2.3.3 Documentation of incidents permitted provided that Point 2.3.2 is fulfilled; otherwise documentation of all product-relevant parameters (vulcanization time, temperature, pressure, ...). 2.3.5 Filling study on production mold 2.3.6 Specification and assurance of a toleranced, maximum water content in hydraulic systems for supplies to DAIMLER AG. 2.3.7 Assembly of stops under flow 2.3.8 DAIMLER AG shall be notified in time before planned process relocations so that all approvals and sampling are completed before production starts 2.3.9 Creation of test plans, provision of inspection, test and measuring equipment for the determination of the quality characteristics, qualification of personnel

Supplier Supplier

Supplier Supplier Supplier Supplier Supplier Supplier

2.4

Establishment of capability evidence


Responsible Supplier

Capability shall be determined on the component based on the defined characteristics and tolerances (Section 2.1.2). Process capability evidence shall be coordinated at the early audit (Section 2.2.9) and before concept design of the production mold. Determination of capability evidence in analogy with VDA 4.1 process model B. Batches and cavity influences shall be taken into account. Short-term: to be presented at the time of Quality-Gate B / Quality-Gate 2, production test 2, initial sample Statement of each cavity from one shot. Measurement of temperature distribution in mold. Statement and specification of representative cavities (at least 2). At least 50 consecutive shots shall be measured for each representative cavity. Preliminary process capability and long-term capability: in analogy with VDA 4.7

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2.5

Guideline for stress analysis

This guideline specifies minimum requirements for the computational design of chassis mounts, isolators and bushings using the FE method.

2.5.1

Computer model

The computer model represents an elastic model of the elastomer body. It consists of hexahedron or square tetrahedron elements and is a 3D model. Symmetries may be used (depending on the load case). Metal parts are rigid or are simulated by rigid fixing.

Example:

Computer model for the load case transverse force in stop direction (1/8)

With regard to the mesh resolution, a feasible compromise is required between model quality and model size. Square tetrahedron models require a higher-resolution mesh than hexa models, but are easier to generate using automatic mesh generators. 2.5.2 Example Example:

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2.5.2

Boundary conditions

Window sheet (not modeled) surface nodes fixed in the 3 translational directions

Stop plug (not modeled)

Core (rigid element)

Central node of the core for applying loads (shift or twist)

Non-linearities caused by major deformations and contact changes as well as incompressible material behavior shall be taken into account in the computation.

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2.5.3 2.5.3.1

Load cases Pre-loads (static)

Shrinkage due to cooling during production ( T) Calibration (radial shift of nodes with contact to sleeve) Assembly (with slotted sleeve) KO position (shift of central node in core)

2.5.3.2

Working loads (quasi-static), half of maximum amplitude

Transverse shift Longitudinal shift in direction of mount/isolator axis Cardanic twist around both lateral axes Torsion around longitudinal axis Superimposition of 3 most important load directions, in each case by a given shift / twist of the central node Where high loads are concerned, convergence problems often occur due to extreme mesh distortions leading to an abortion of the computation / long computation periods. Computation up to half the maximum shift / twist amplitude is therefore specified as minimum requirement.

2.5.4

Evaluation

Spring characteristic for all working load directions Tensile stress distribution (1) on the surface of the rubber body Tendency towards wrinkling in pressure area The objective is the development of a mount/isolator contour with sufficient durability and minimum bulk volume by a (tensile) stress distribution which is as uniform as possible and by avoiding wrinkling on the pressure side. The frequency of load cycles in the different directions shall be taken into account when evaluating the computational results. Pre-optimisation with rotationally symmetric computational models and the application of numerical optimization methods make useful contributions towards the reduction of the modeling and computation input.

2.5.5

Outlook

The reliability of the mount/isolator design should be further increased significantly in future by means of durability computations using in-phase superimposition of the operational forces and accumulation of the material damage. In order to achieve this objective, however, the computational method must be still further developed significantly with regard to the numerical stability and suitable damage parameters.

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2.6

Production
2.6.1 2.6.1.1 2.6.1.2 Incoming goods area, warehouse, shelf life, material flow During delivery and while storing care shall be taken to ensure that the goods are protected against water (suitable containers, canopy in unloading area). No goods may be stored outdoors. Storage conditions (temperature, time) shall be specified for each raw material and adhered to. Use-by dates shall be indicated and systematically monitored (including the containers in the mixing room). When dates are exceeded, the raw materials shall be barred. A test instrument for qualitative identity checking (e.g.: IR, TGA analysis) shall be available for incoming inspection of raw materials and mixture monitoring. An individual test plan shall be created for each raw material, purchased part and semi-finished product. During incoming inspection, own tests shall be performed at least on a random basis (assessment of the supplier's test report is not sufficient). The individual batches (including bulk goods) shall not be put into storage until the incoming inspection has been passed. Individual containers (including those already opened) shall be marked clearly (in color, if possible) with the product designation, batch, release status, and the manufacturing and use-by dates. The warehouse management system shall offer a simple facility for carrying out evaluations of the current inventory, including in particular an overview of the use-by dates. Transportation of parts or raw and finished materials with no risk of confusion shall be ensured. The part and material status shall be clearly recognizable. Rejected goods shall be collected in marked containers and evaluated.

2.6.1.3 2.6.1.4

2.6.1.5 2.6.1.6 2.6.1.7 2.6.1.8 2.6.1.9

2.6.1.10 For back-up samples and material returned from production, the retention period and alternate usage shall be clearly defined. 2.6.1.11 Mixtures shall be wrapped so that they are protected against contamination. Contamination resulting from wood chips and packaging material (or conceivably pallets) shall be prevented.

2.6.2 2.6.2.1

Feed stock / Elastomer / Purchased parts The processability of any new materials presented shall be assured. In addition to the specifications on drawings, separate material specifications shall be available including all relevant functional characteristics (see DBL 5555). During material development, care shall be taken that the availability of the raw materials is ensured throughout the intended delivery period. Contingency strategies shall be established for each raw material used. In the event of non-availability of raw materials, Daimler AG shall be informed without delay. An approval system shall exist and shall be applied consistently.

2.6.2.2

2.6.2.3

2.6.3 2.6.3.1 2.6.3.2

Weighing During the filling of the containers in the mixing room care shall be taken to ensure that raw materials cannot be confused. The individual components shall be weighed in at the weighing stations (identity and weight) using a computer-based system. The procedure in the event of deviations shall be clearly defined.
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DBL 6218 2008-07, Page 9 2.6.3.3 2.6.3.4 The tolerance (< 1 % to be targeted) shall be adapted to the weighed-in portion. Any carry-over of chemicals shall be excluded, including in the event of overweighing.

2.6.4 2.6.4.1 2.6.4.2 2.6.4.3

Loading of mixer The addition of the bulk components plasticizer and carbon black shall be ensured with regard to identity and weight. In order to avoid temperature fluctuations when loading the mixer, the mixing constituents shall be stored appropriately. Mixer loading shall be specified with regard to time, components and component temperature and shall be executed within the tolerances.

2.6.5 2.6.5.1 2.6.5.2

Mixing process Only the mixing process specified for the product shall be used. All significant parameters for the mixing process shall be specified and toleranced. During the mixing process, these parameters shall be monitored and documented (e.g. stamping pressure, speed, temperature in mixing chamber, energy input). Malfunctions shall be evaluated, documented and relevant actions initiated. The use of energy as regulation and control variable shall be targeted. Ancillary systems such as cooling and grease pumps shall be monitored and checked. Following maintenance of production facilities (e.g. mixer, roll mill) which could have an impact on a quality characteristic, the product quality shall be verified by the supplier following restarting.

2.6.5.3 2.6.5.4

2.6.6

Roll mill / Stock blender Homogenization and cooling shall be adapted to the individual mixture and performed in a defined way (roll temperature, gap, speed, dwell time, number of changes on the stock blender). The mixing temperature shall be directly monitored. Related cooling systems shall be monitored. Contamination of the mixture shall be excluded (e.g. no mixture dropping on the floor).

2.6.7

Batch-off system Release agents and application quantities shall be specified. All important parameters shall be specified and toleranced. These shall be monitored and maintained (e.g. cooling time, temperature). Malfunctions shall be evaluated, documented and relevant action taken.

2.6.8

Strainer (if used) The strainer process shall be adapted to the elastomer mixture, and important parameters shall be defined with tolerances (e.g. mesh size of screen, injection speed, number of passes, dynamic pressure, temperature, cooling). Screen residues shall be analyzed with regard to their provenance. Screen packs shall be protected against confusion. The system shall be protected against contamination. Any impact on the vulcanization properties (reduction of shelf life, any prevulcanization) shall be determined.

2.6.9

Analysis of mixture For each mixture, a test plan with inspection characteristics, tolerances and frequencies shall be specified. The use of mixtures shall also be described by means of envelope curves in rheovulcameters.

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2.6.10 Storage of mixture / Shelf life 2.6.10.1 The storage conditions shall be specified. For the maximum storage period, the following parameters shall be taken into account: temperature in warehouse, different sensitivities of the polymers, accelerated and non-accelerated mixtures. 2.6.10.2 The process for reuse of expired mixtures and residual materials, if applicable, shall be clearly defined. Any subsequent use shall be documented. 2.6.10.3 In the event of transportation of accelerated mixtures or other reactive input materials, the effects of the transportation shall be examined (the maximum permissible temperature spectra shall be determined and monitored). If necessary, refrigerated means of transport shall be used.

2.6.11 Input material/metal parts 2.6.11.1 Product-related work instructions including processes, abrasive and blasting time, shall be available for the blasting of metal parts. The timely replacement of the abrasive shall be ensured. The blasting results to be achieved shall be monitored by means of suitable tests (surface roughness, film break). 2.6.11.2 A reasonable durability shall be specified for the blasted and pre-treated parts. 2.6.11.3 The part status shall be visible at any time.

2.6.12 Coating of metal parts 2.6.12.1 All important parameters for the coating and drying process shall be specified and provided with tolerances. They shall be monitored, observed and documented (e.g. injection pressure, holding time in drier, viscosity). Malfunctions shall be evaluated, documented and relevant actions initiated. In case of 2-component systems, safeguards shall be in place to confirm that the primer has been applied. 2.6.12.2 Changes in the pre-treatment process necessitate a new parts approval process. 2.6.12.3 An approval sequence, a specific test plan and an adequate shelf life shall be defined for binders. 2.6.12.4 Reference samples shall be available for visual inspection. 2.6.12.5 Suitable measuring equipment for layer thickness measurements shall be available (accuracy < layer thickness).

2.6.13 Vulcanization 2.6.13.1 The vulcanization process shall be adapted to the product. 2.6.13.2 The process shall be described unambiguously in the production plan. All important parameters such as vulcanization time, pressure, cycle time and temperature shall be toleranced and continuously monitored. Malfunctions shall be evaluated, documented and relevant actions initiated. The process data shall be archived and used for the creation of capability evidence. 2.6.13.3 The process technology interrelationships between the mixing properties, process parameters and vulcanizate properties shall be known. As a result of systematic examinations, process windows shall be defined. Permissible dwell times in the extruder shall be known depending on the temperature and mixture and assured by means of rheo-vulcameter curves. 2.6.13.4 Where vacuum molds are used, the vacuum shall be continuously monitored. 2.6.13.5 If the limit value is exceeded, the system shall signal a malfunction. Malfunctions shall be indicated, evaluated, documented and relevant actions initiated. The process for reuse, if applicable, shall be
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DBL 6218 2008-07, Page 11 clearly defined and assured by means of internal release analyses. Any subsequent use shall be documented. 2.6.13.6 The handling of coated inserts shall be specified. Any preheating, the holding time in the mold and the contamination shall be considered. 2.6.13.7 For the case of system standstill periods, care shall be taken to ensure that any pre-crosslinked mass cannot enter the downstream process (ejection of elastomer mass from the cylinder and runner system). Following a change of mixture, any carry-over of waste rubber shall be prevented. 2.6.13.8 Process parameters shall be defined specific to each mixture. 2.6.13.9 After use of a release agent, a minimum flash-off time and maximum dwell time in the mold shall be defined. 2.6.13.10 The mold history shall be documented with reference to event and shot numbers. 2.6.13.11 Flash shall be removed completely (in one piece, if possible). 2.6.13.12 Remaining mold separating skins are not permissible within hydraulic systems. 2.6.13.13 Parts produced during machine set-up shall be scrapped.

2.6.14 Hydraulic systems 2.6.14.1 The maximum water contents shall be defined and toleranced. The fluid shall be continuously cleaned. 2.6.14.2 During filling, care shall be taken to ensure that no air inclusions are formed and that no contamination can enter the system.

2.6.15 Determination of part properties (final inspection) 2.6.15.1 Using appropriate measuring methods, the properties of the vulcanizate shall be determined on a batch-by-batch basis (see Section 2.2.7). Besides the dimensional and functional final inspection, material identity checks shall also be performed, at least within the context of requalifications. 2.6.15.2 Adequate test capacity for the determination of the functional characteristics shall be available. Temperature control facilities are indispensable. 2.6.15.3 In-process function tests such as static and dynamic characteristics, binding tests and durability tests shall be performed at scheduled intervals. 2.6.15.4 The lighting of test stations. e.g. for visual surface examination (visual inspection), shall be appropriate for its purpose. 2.6.15.5 Reference samples and currently occurring product defects shall be placed at the test stations. 2.6.15.6 For mechanical tests on parts, the relevant process parameters shall be documented. 2.6.15.7 The fracture pattern, location and force shall be determined when checking adhesion and vulcanization.

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Part 2 : General conditions, versions, test methods

3.1

Field of application, general requirements

This Supply Specification renders the Requirement Specifications of the Working Group Elastomer Mounts (AK LH 10) of the Strategy Group Durability/Test Methods (strategy group of the automotive manufacturers Audi, BMW, Daimler AG, Porsche and VW) valid within Daimler AG for the marque Mercedes-Benz. In case of components where the above mentioned product versions cannot be assigned unambiguously or whose stress types are not completely covered by the test guidelines, the relevant applicable test guideline shall be specifically agreed in each individual case between supplier and buyer. If required, stipulations deviating from these test guidelines shall be agreed in individual cases. The technical requirements specified in existing Daimler AG Supply Specifications have overriding validity. These Supply Specifications shall additionally be listed on the drawing (e.g. for elastomers: DBL 5557, DBL 5558 or for corrosion protection).

3.2

General properties of the materials, raw materials and supply condition

The general conditions in accordance with DBL 5555 and DBL 8585 shall be observed. In addition, the "Purchase Conditions for Production Materials and Spare Parts for Motor Vehicles" and "MB Special Terms" are deemed constituent parts of the agreement.

3.3

Technical data

AK Requirement Specifications LH 10 "Index f" of the Strategy Group Durability/Test Methods of the automotive manufacturers Audi, BMW, Daimler AG, Porsche and VW.

3.4

Tests

AK Requirement Specifications LH 10 "Index f" of the Strategy Group Durability/Test Methods of the automotive manufacturers Audi, BMW, Daimler AG, Porsche and VW.

3.5

Other applicable standards

Special Purchase Conditions, MB-Special Terms, DBL 5555, DBL 8585, AK Requirement Specifications LH 10 "Index f" of the Strategy Group Durability/Test Methods of the automotive manufacturers Audi, BMW, Daimler AG, Porsche and VW.

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