[dipen]

Since a lot of metals are being discussed, could anyone highlight the pros and cons of the discussed aluminum grade, mild steel, SS.

[vikram_d]

Jitu, I would still recommend using SS304. It will not give you any problems in the long run. Only drawback of SS is that it will be three times as heavy, but a 8mm thick plate will be enough instead of 12mm of aluminium.

If you want to use aluminium only then look for 7075-T6 (this is really exotic stuff). This has double the strength of 6061-T6. But this material will cost you a bomb. 7075 basically is an alloy of aluminium & zinc. If you manage to find this and use it then make sure that you hard anodize it as this material corrodes very easily. Hard anodizing needs to be done after all other operations are completed. Even 6061-T6 will need to hard anodized if you use that.

[ananthkamath]

Originally Posted by vikram_d

If you want to use aluminium only then look for 7075-T6 (this is really exotic stuff). This has double the strength of 6061-T6.

Quite unnecessary. We've made several prototype suspension parts for military off-road vehicles from 6061-T6 and there hasn't been a single low-cycle fatigue related failure during durability testing.

That being said, I would not bother with the 1 or 2 kg weight saving that either of these materials would provide over standard mild or stainless steel. In an application like this you can simply use 4 or 5 mm cold-rolled mild steel plate for the top hat and round bar stock for the bearing housings.

[Mpower]

Originally Posted by vikram_d

6061 is widely available in India but not 6061-T6.

T6 is just the heat treat, same alloy. Something that can be done.

[vikram_d]

Not everybody over here is equipped & confident of heat treating (tempering in this case) aluminium. Its is best done while manufacturing itself. I got it tried once, with disastrous results. At the end all I got was a blob of aluminium. All this in spite of me having given the heat treatment process cycle to my vendor.

@Dipen - That's a topic for another thread. Will compile some basic stuff and put it down shortly.

[Ford Rocam]

Originally Posted by vikram_d

Hard anodizing needs to be done after all other operations are completed. Even 6061-T6 will need to hard anodized if you use that.

Vikram, When we say hard anodizing is needed, what exactly is that process?

[ashthedivx]

Hey Jitu,

Commendable work and enthusiasm mate !!

Have you found the metal material you are looking for ?? If NO, then I have a very good friend of mine into the metal business and can can arrange the same, let me know the specifications and size if you are still looking out. Though primarily inquiring 6061-TR6 should be available, but he needs the required size for being more specific.

Cheers

[xmOD]

jitu,

hard anodizing is an extension of the anodizing process. Typically, anodizing involves immersing the aluminium in a bath of sulphuric acid which is known as electrolyte and then running a low voltage electric current through the electrolyte. This is how most aluminium is treated but because of this normal normal anodizing, a thin layer of aluminium oxide or rust forms over the metal. To get a more thicker coating of rust to get rid of any small dents or holes in the metal, we use hard anodzing. To hard anodize the aluminium, we just cool the electrolyte, sulphuric acid, to the freezing point of water and the amoutn of electric current we supplied earlier is increased.

Hard anodized aluminium is much better for applications in performance parts for automobiles as the metal has to go through varying degrees of heat and stress and the aluminium produced is very hard and solid.

Hope I could help you.

[vikram_d]

Thanks xmod for the perfect explanation.

[Ford Rocam]

Thanks for the explanation Xmod.

Meantime got hold of 6061-T6 (took some time though) & it had the grade marked from the factory itself so i guess it does not need any further testing.


Some W.i.P pics





& it has come out well



Bearing sits fine



Complete assembly

with Springs


Monday work starts on camber plate.

[Akshay1234]

ah so this is what you were doing yesterday? lol

[navpreet318]

Good work and the Ali actually looks great in quality too.

[ported_head]

I haven't followed the whole thread yet, but another custom job for Jitu bhai.

I don't see any fillet radii at any of the sectional changes anywhere. Isn't that necessary? If it were to fail, it would most likely start at the cross sectional changes.

[amit_mechengg]

Originally Posted by ported_head

I haven't followed the whole thread yet, but another custom job for Jitu bhai.

I don't see any fillet radii at any of the sectional changes anywhere. Isn't that necessary? If it were to fail, it would most likely start at the cross sectional changes.

exactly the same thought that came to my mind, i was just about to point that stresses will build up at the outer edge at the steps. i think a 2mm radius will be fine.

[Ford Rocam]

Originally Posted by ported_head

I don't see any fillet radii at any of the sectional changes anywhere. Isn't that necessary? If it were to fail, it would most likely start at the cross sectional changes.

Originally Posted by amit_mechengg

exactly the same thought that came to my mind, i was just about to point that stresses will build up at the outer edge at the steps. i think a 2mm radius will be fine.

Which steps you are referring to? top/bottom?