Cross member

Iron sand casting in the truck frame                       - An optimal solution

Developing reliable solutions for the largest and heaviest vehicles on our roads - this requires not only know-how in design development, construction and production, but above all comprehensive expertise in the development of lightweight components. After all, components in trucks in particular are subject to extreme stresses, but should not have a negative impact on the vehicle weight. This is precisely what has been achieved with the one-piece cast cross member from GF Casting Solutions, manufactured at our iron casting plant in Kunshan (China).

With more than 260 employees and modern production lines, we have an annual production capacity of 60,000 tons. The core activities in Kunshan are the production and machining of lightweight solutions in iron sandcasting. In addition, an in-house R&D department allows high-level customer support and stable production processes.  We support our customers in the development and production of high-complex lightweight components to continuously reduce weight.W ith high functional integration and our development know-how, we offer the entire value chain to the ready-to-mount solution.

In the frame of the truck

The frame of the truck not only plays a supporting role, but is also important for the connection of other components. For this reason, the individual components within the frame must be optimally matched to each other and achieve the right balance between rigidity and flexibility. The same applies to the cross members, which are attached to the front and rear of the frame like the rungs of a ladder.

Advantages of a one-piece cast solution

With the cross member, we show how a one-piece cast solution in the frame of the truck can cover the above requirements. The fact that it consists of only one cast piece means that numerous functions can be integrated into one casting, saving the customer machining and assembly operations. The example of the cross member shows that connection points to the frame, to the axle support, to towing units and to smaller add-on parts can be integrated into the casting. The iron cast solution thus offers increased flexibility and design freedom, which (depending on the design) has a positive effect on vehicle behavior. 

Safety first

During development, however, the focus is also on safety, as the frame is a crash-relevant component. The stiffness of the component must be precisely coordinated with the customer. To this end, our developers must be involved in the development process as early as possible and have the necessary data at their disposal. Nothing then stands in the way of the optimum casting solution - simulations and extensive component testing in our R&D department in Kunshan round off our services.