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Lightweight Complexities
The focus of modern lightweight technology is on reducing vehicle weight. Nevertheless: lighter cars are anything but trimmed down versions of their heavier counterparts. In fact, they are equal when it comes to comfort, driving dynamics and safety. ZF engineers have achieved several breakthroughs in the field of lightweight technology. State-of-the-art examples include transmission housings made from metal alloys and new chassis components that weigh significantly less thanks to innovative designs and intelligent use of materials. Manufacturing advanced lightweight components requires complex processes. Based on pioneering production expertise, these have been developed and implemented over the past few years in ZF series production operations.
ZF-specific production processes
Seventeen carefully coordinated steps are required to transform a small section of aluminum rod into a 40cm-long outer tube for a lightweight shock absorber. Since no system available on the world markets was capable of duplicating the process parameters and sequence required, ZF engineered its own system. The OPAL (optimized aluminum) line is based on the flow production principle. In addition to meeting the high standards for trouble-free manufacturing processes, it enables short reaction and throughput times. And this increases operating efficiency. The end product is something to see: outer tubes with varying wall thicknesses used inside lightweight shock absorbers. This combination reduces weight by up to 5kg. The innovative components in this design are manufactured according to the lightweight principle followed by ZF engineers: reinforce the material where this is functionally required while keeping it as thin as possible in other parts of the workpiece.
Promoting lightweight construction
Weight can also be saved inside the shock absorber. Integrating lightweight construction into the hollow shock absorber piston rods demanded creativity from ZF engineers along with a willingness to explore atypical processes. The innovative tubes made from temperable steel are permanently joined in a friction welding process. This approach ensures the same functional strength attainable with the conventional method of milling the piston rods from solid metal. The people at ZF are confident that lightweight concepts have enormous potential for the future. That's why the company is moving forward with special engineering projects. This involves bringing together company-wide synergies, pooling available resources, and participating in research projects aimed at promoting lightweight technologies. This will help ensure that ZF remains a leader in the field of lightweight construction.
Last Update: 11.06.2008