Name: Bellow rubber
Model: Bajaj Re
Quality: A plus
Warranty: 3 Months'
Delivery: 30 Days
Bajaj Bellow Rubber optional Material and quality control
Common materials and characteristics
Chloroprene rubber (CR), thermoplastic polyurethane (TPU), silicone rubber (VMQ).
1,Chloroprene rubber is resistant to oil, ozone and aging, with moderate cost, but its disadvantages are poor elasticity at low temperature and easy cracking in extreme environments.2,Thermoplastic polyurethane (TPU) has advantages of high strength, wear resistance and low temperature resistance (-40℃~120℃), but its disadvantages are high cost and complex processing technology.
3,Silicone rubber (VMQ) has advantages of high temperature resistance (-60℃~200℃) and environmental protection, and is used in high-end or electric vehicles. Its disadvantages are low mechanical strength and need to be used with reinforcing fibers.
4,Acrylic rubber (ACM)
Applicable scenarios: high temperature environment (such as close to the engine or exhaust system).
2. Key points of quality control
1. Raw material control
Supplier audit: Ensure that the rubber/TPU supplier is IATF 16949 certified.
Component testing: Check the ratio of anti-aging agent and plasticizer (such as ASTM D2000 standard).
2. Production process control
Vulcanization process (rubber): Monitor temperature, time, pressure to avoid under-sulfurization or over-sulfurization.
Injection molding process (TPU): Control melt temperature and cooling rate to prevent bubbles or shrinkage.
Mold maintenance: Clean regularly to avoid burrs or uneven thickness (wall thickness tolerance is usually ±0.1mm).
3. Performance test
Durability: Bench simulation test (such as 500,000 reciprocating motions without cracks).
Environmental adaptability:
High temperature aging (hardness change ≤15% after 120℃×72h).
Low temperature brittleness (folding without cracks after -40℃×24h).
Medium resistance: Soaked in gear oil (such as GL-5) for 72h, the volume expansion rate is ≤10%.
4. Finished product inspection
Dimension inspection: clamp groove position, inner diameter/outer diameter (CMM measurement).
Air tightness test: Inflate to 0.1MPa, maintain pressure for 3 minutes without leakage.
Appearance inspection: No scratches or impurities (according to ISO 9001 appearance standard).
5. Vehicle loading verification
Road test (such as gravel road, muddy road) verifies the sealing and fatigue life of the dust cover.
III. Common failure modes and countermeasures
Cracking/aging: Optimize the formula (such as adding anti-UV agent) to avoid inventory overdue (the inventory period of rubber parts is usually ≤1 year).
Grease leakage: Improve the clamp design (such as double-layer metal clamp) to ensure the assembly torque (such as 5±0.5 N·m).
Installation damage: Use pre-lubrication design and train assembly workers to use special tools.
How to verify the quality of the bajaj bellow rubber
Judging the quality of the automotive ball cage cover (dust cover) requires a comprehensive evaluation from multiple aspects such as materials, process, performance, and installation adaptability. The following are specific judgment methods:
1. Appearance inspection
Material touch
High quality: rubber parts are soft and elastic (TPU parts are tough and burr-free), and the surface is smooth and free of particles.
Poor quality: hard material, rough surface or cracks (may be recycled rubber or improper storage).
Thickness uniformity
Pinch the folds of the dust cover with your hands to check whether the wall thickness is consistent (unevenness can easily lead to early rupture).
Mold process
Observe whether the mold line is flat (inferior products have many burrs on the mold line and are prone to oil leakage).
2. Performance test (conducted when conditions permit)
Oil resistance test
Soak the dust cover in gear oil (such as GL-5) for 24 hours to observe whether it expands or becomes sticky (the volume change of high-quality products is ≤5%).
Low temperature elasticity
Put it in a -40℃ freezer for 2 hours and fold it. It is qualified if there is no crack (key test in northern regions).
Tensile strength
Manually stretch the dust cover, high-quality products rebound quickly and have no permanent deformation (reference standard: SAE J2642).
3. Compatibility check
Matching degree with half shaft
Before installation, confirm that the inner diameter of the dust cover fits tightly with the half shaft journal (too large a gap will cause it to fall off easily).
Check whether the clamp groove position is accurate (the clamp of inferior products cannot be locked).
Dynamic interference check
After loading, turn the steering wheel to the left and right directions to observe whether the dust cover rubs against the surrounding parts.
4. Brand and packaging
Brand logo
Prefer the original supporting brand (such as GKN, NTN, SDS) or well-known aftermarket brands (such as Meyle, Corteco).
Be wary of "three no" products without brand and production date.
Packaging information
Authentic packaging usually marks the material (such as "CR" "TPU"), applicable model, production date and certification (ISO/TS 16949).
5. Common characteristics of inferior ball cage sleeves
Punchy smell: inferior rubber contains excessive sulfide or plasticizer.
Abnormal color: genuine rubber is mostly black or dark gray. If the color is shiny or whitish, it may be adulterated.
Crude clamp: use single-layer iron clamp (high-quality products are double-layer stainless steel or spring clamp).
6. Quality verification in actual use
Short-term verification: drive 500 kilometers after installation to check whether there is grease leakage or cracks in the sleeve.
Long-term verification: no cracking or aging within 1 year of normal use (the life of high-quality products is usually 3-5 years).
Summary and suggestions
Give priority to original parts or brand parts, and avoid low-priced and inferior products.
Use special tools during installation to avoid human damage (such as deformation caused by over-tightening of the clamp).
Regular maintenance and inspection: visually check the status of the dust cover every 20,000 kilometers and replace damaged parts in time.
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