JP5496926B2 - Rack bar and manufacturing method thereof - Google Patents

Rack bar and manufacturing method thereof Download PDF

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JP5496926B2
JP5496926B2 JP2011014136A JP2011014136A JP5496926B2 JP 5496926 B2 JP5496926 B2 JP 5496926B2 JP 2011014136 A JP2011014136 A JP 2011014136A JP 2011014136 A JP2011014136 A JP 2011014136A JP 5496926 B2 JP5496926 B2 JP 5496926B2
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punch
tooth
rack
corrugated plate
forming
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JP2012154422A (en
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幸孝 國本
盛己 田代
久志 杣田
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Toyota Motor Corp
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Description

本発明は、自動車用のステアリング装置に使用されるラックバーおよびその製造方法に関するものである。   The present invention relates to a rack bar used in a steering apparatus for an automobile and a manufacturing method thereof.

従来、この種のラックバーとしては、丸棒状（円柱状）の素材にラック歯を切削加工で形成したものが用いられてきた。   Conventionally, as this kind of rack bar, a round bar (columnar) material formed by cutting rack teeth by cutting has been used.

ところが、このようなラックバーでは、ラック歯の強度を高めるべく歯幅を大きくしようとすると、必然的に素材が大断面化して重くなる。そのため、自動車の燃費が悪化するとともに、二酸化炭素などの温室効果ガスの排出量が増え、さらに、ステアリング操作フィーリングが悪化するという不都合があった。   However, in such a rack bar, if the tooth width is increased in order to increase the strength of the rack teeth, the material inevitably becomes larger and heavier. As a result, the fuel consumption of the automobile deteriorates, the amount of greenhouse gas emissions such as carbon dioxide increases, and the steering operation feeling deteriorates.

そこで、近年、円筒状の素材にラック歯を形成した中空のラックバーが提案されている（例えば、特許文献１参照）。   Therefore, in recent years, a hollow rack bar in which rack teeth are formed on a cylindrical material has been proposed (see, for example, Patent Document 1).

特開２００６−２２４８２２号公報JP 2006-224822 A

しかしながら、こうした中空のラックバーでは、円筒状のバー本体の一部（円弧断面部分）を平坦状に塑性加工した後、その部位にラック歯を形成する。そのため、ラック歯は、バー本体の基準円（外径円）がピッチ平面によって切り取られた弦の長さ以下の歯幅しか得られない。その結果、このラックバーと噛み合うピニオン軸の歯元応力が増大し、ピニオン歯の耐久強度が低下するという課題があった。   However, in such a hollow rack bar, after a part of the cylindrical bar body (arc cross-section part) is plastically processed into a flat shape, rack teeth are formed at the part. Therefore, the rack teeth can only have a tooth width equal to or less than the length of the chord in which the reference circle (outer diameter circle) of the bar body is cut by the pitch plane. As a result, there is a problem that the root stress of the pinion shaft that meshes with the rack bar increases, and the durability of the pinion teeth decreases.

本発明は、このような事情に鑑み、軽量化を図ると同時にピニオン歯の耐久強度を高めることが可能なラックバーを提供することを第１の目的とする。また、このようなラックバーにおいて、ラック歯の肉厚および歯幅を確保することが可能なラックバーの製造方法を提供することを第２の目的とする。   In view of such circumstances, it is a first object of the present invention to provide a rack bar capable of reducing the weight and increasing the durability of pinion teeth. In addition, a second object of the present invention is to provide a method for manufacturing a rack bar capable of ensuring the thickness and width of the rack teeth in such a rack bar.

かかる目的を達成するため、本発明者は、ラックバーを軽量化すべく、円筒状の素材をバー本体として採用するとともに、ラック歯の歯幅を増大させてピニオン歯の耐久強度を高めるべく、素材の上部にラック歯を形成するのに先立ち、この部位をバー本体の基準円（外径円）の外側に膨らませる形で平板状に塑性変形させることに着目し、本発明を完成するに至った。   In order to achieve this object, the present inventor has adopted a cylindrical material as a bar body in order to reduce the weight of the rack bar, and to increase the durability of the pinion teeth by increasing the tooth width of the rack teeth. Prior to forming the rack teeth on the top of the bar, the present invention was completed by paying attention to plastically deforming this part into a flat plate shape inflating outside the reference circle (outer diameter circle) of the bar body. It was.

すなわち、請求項１に記載の発明は、自動車用のステアリング装置に使用され、所定の基準円に対応する外径を有する円筒状のバー本体と、ピッチ平面に沿って形成されたラック歯とを備え、前記ラック歯の歯幅は、前記基準円が前記ピッチ平面によって切り取られた弦の長さより広いラックバーであって、円筒状の素材の下部が下型で支持されるとともに、前記素材の外径以上の幅のパンチ挿入口が形成された上型で当該素材の上部が支持され、さらに、前記素材の中空部に心金が挿入されて当該素材の下部に接触した状態で、波形板状成形パンチを前記パンチ挿入口に挿入して前記素材の上部を押圧することにより、前記素材の上部を波形板状に塑性変形させる波形板状変形工程と、前記波形板状成形パンチに代えて平板状成形パンチを前記パンチ挿入口に挿入して前記素材の上部を押圧することにより、前記素材の上部を平板状に塑性変形させる平板状変形工程と、前記素材の上部にラック歯を形成する歯形成工程とを含む製造方法によって製造されたラックバーとしたことを特徴とする。 That is, the invention according to claim 1 is used in a steering apparatus for an automobile, and has a cylindrical bar body having an outer diameter corresponding to a predetermined reference circle, and rack teeth formed along a pitch plane. The rack tooth has a tooth width that is a rack bar whose reference circle is wider than the length of a chord cut by the pitch plane, and a lower portion of a cylindrical material is supported by a lower mold, and the material In the state where the upper part of the material is supported by the upper die formed with a punch insertion opening having a width equal to or larger than the outer diameter of the material, and further, a mandrel is inserted into the hollow part of the material and is in contact with the lower part of the material. Instead of the corrugated plate forming punch, a corrugated plate forming step of plastically deforming the upper portion of the material into a corrugated plate shape by inserting a plate shaped punch into the punch insertion port and pressing the upper portion of the material. Flat plate forming punch A plate-shaped deformation step of plastically deforming the upper portion of the material into a flat plate shape by inserting it into the punch insertion slot and pressing the upper portion of the material; and a tooth forming step of forming rack teeth on the upper portion of the material. The rack bar is manufactured by the manufacturing method including .

また、請求項２に記載の発明は、請求項１に記載の構成に加え、前記ラック歯の歯幅は、前記バー本体の外径に一致していることを特徴とする。   The invention according to claim 2 is characterized in that, in addition to the configuration according to claim 1, the tooth width of the rack tooth coincides with the outer diameter of the bar body.

一方、請求項３に記載の発明は、円筒状の素材の下部が下型で支持されるとともに、前記素材の外径以上の幅のパンチ挿入口が形成された上型で当該素材の上部が支持され、さらに、前記素材の中空部に心金が挿入されて当該素材の下部に接触した状態で、波形板状成形パンチを前記パンチ挿入口に挿入して前記素材の上部を押圧することにより、前記素材の上部を波形板状に塑性変形させる波形板状変形工程と、前記波形板状成形パンチに代えて平板状成形パンチを前記パンチ挿入口に挿入して前記素材の上部を押圧することにより、前記素材の上部を平板状に塑性変形させる平板状変形工程と、前記素材の上部にラック歯を形成する歯形成工程とを含むラックバーの製造方法としたことを特徴とする。   On the other hand, in the invention according to claim 3, the lower part of the cylindrical material is supported by the lower mold, and the upper part of the material is formed by an upper mold in which a punch insertion opening having a width larger than the outer diameter of the material is formed. In a state where a mandrel is inserted into the hollow portion of the material and is in contact with the lower portion of the material, a corrugated plate-shaped molding punch is inserted into the punch insertion port and the upper portion of the material is pressed. A corrugated plate deformation step of plastically deforming the upper part of the material into a corrugated plate, and a flat plate forming punch instead of the corrugated plate forming punch is inserted into the punch insertion port to press the upper part of the material Thus, the manufacturing method of the rack bar includes a flat plate deformation process in which the upper portion of the material is plastically deformed into a flat plate shape, and a tooth formation step of forming rack teeth on the upper portion of the material.

また、請求項４に記載の発明は、請求項３に記載の構成に加え、前記波形板状変形工程において、前記波形板状成形パンチとして、複数の凸部が形成された押圧面を有するものを用いることにより、前記素材の上部に複数の凹部を形成して波形板状に塑性変形させることを特徴とする。   Moreover, in addition to the structure of Claim 3, the invention of Claim 4 has the press surface in which the several convex part was formed as the said corrugated plate-shaped shaping | molding punch in the said corrugated plate-shaped deformation | transformation process. Is used, and a plurality of concave portions are formed on the upper portion of the material to be plastically deformed into a corrugated plate shape.

また、請求項５に記載の発明は、請求項３または４に記載の構成に加え、前記平板状変形工程において、前記素材の上部を平板状に塑性変形させる際に当該素材の上部の肉厚を当該素材の下部の肉厚より厚くすることを特徴とする。   Moreover, in addition to the structure of Claim 3 or 4, in invention of Claim 5, when the upper part of the said material is plastically deformed to flat form in the said flat deformation process, the thickness of the upper part of the said raw material Is made thicker than the thickness of the lower part of the material.

また、請求項６に記載の発明は、請求項３乃至５のいずれかに記載の構成に加え、前記歯形成工程において、前記平板状成形パンチに代えて歯形成パンチを前記パンチ挿入口に挿入して前記素材の上部を押圧することにより、前記素材の上部にラック歯を形成することを特徴とする。   According to a sixth aspect of the present invention, in addition to the configuration according to any of the third to fifth aspects, in the tooth forming step, a tooth forming punch is inserted into the punch insertion opening instead of the flat plate forming punch. Then, by pressing the upper part of the material, rack teeth are formed on the upper part of the material.

また、請求項７に記載の発明は、請求項３乃至６のいずれかに記載の構成に加え、前記心金は、前記素材のラック歯を形成する部位に対向する反力部が、かまぼこ形を呈し、前記素材の内径の半分にほぼ等しい曲率半径を有する曲面状の下面と、前記素材の内径より僅かに狭い幅を有する平坦な上面とを備えることを特徴とする。   In addition to the configuration according to any one of claims 3 to 6, the invention according to claim 7 is characterized in that the mandrel has a kamaboko-shaped reaction force portion that opposes a portion of the material forming the rack teeth. And a curved lower surface having a radius of curvature substantially equal to half of the inner diameter of the material, and a flat upper surface having a width slightly narrower than the inner diameter of the material.

本発明のうちラックバーに係る発明によれば、全体が中空状であるため、中実状（丸棒状）の従来品に比べて、ラックバーを軽量化することができる。しかも、ラック歯の歯幅は、バー本体の基準円がピッチ平面によって切り取られた弦の長さより広いので、このラックバーと噛み合うピニオン軸の歯元応力を減少させ、ピニオン歯の耐久強度を高めることができる。また、このラックバーを製造する際には、素材の上部を波形板状に塑性変形させてから平板状に塑性変形させた後、この部位にラック歯を形成するようにしたことから、ラック歯の肉厚および歯幅を確保することが可能となる。 According to the invention relating to the rack bar of the present invention, since the whole is hollow, the weight of the rack bar can be reduced as compared with the conventional product having a solid shape (round bar shape). In addition, since the tooth width of the rack teeth is wider than the length of the chord cut by the pitch plane of the bar body, the tooth root stress of the pinion shaft that meshes with this rack bar is reduced, and the durability of the pinion teeth is increased. be able to. In addition, when manufacturing this rack bar, since the upper part of the material is plastically deformed into a corrugated plate shape and then plastically deformed into a flat plate shape, rack teeth are formed at this portion. It is possible to ensure the thickness and tooth width of the tooth.

本発明のうちラックバーの製造方法に係る発明によれば、ラックバーを製造する際に、素材の上部を波形板状に塑性変形させてから平板状に塑性変形させた後、この部位にラック歯を形成するようにしたことから、ラック歯の肉厚および歯幅を確保することが可能となる。   According to the invention relating to the rack bar manufacturing method of the present invention, when the rack bar is manufactured, the upper portion of the material is plastically deformed into a corrugated plate shape and then plastically deformed into a flat plate shape, and then the rack bar is attached to this portion. Since the teeth are formed, the thickness and width of the rack teeth can be secured.

本発明の実施の形態１に係る自動車用のステアリング装置を示す斜視図である。BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view showing a vehicle steering apparatus according to Embodiment 1 of the present invention. 同実施の形態１に係るステアリング装置のラックバーとピニオン軸との噛合状態を示す斜視図である。FIG. 3 is a perspective view showing a meshed state between a rack bar and a pinion shaft of the steering device according to the first embodiment. 同実施の形態１に係るラックバーを示す図であって、（ａ）は正面図、（ｂ）は（ａ）のＤ矢視図、（ｃ）は（ａ）のＥ−Ｅ線による拡大断面図である。It is a figure which shows the rack bar which concerns on the same Embodiment 1, Comprising: (a) is a front view, (b) is a D arrow line view of (a), (c) is an expansion by the EE line of (a). It is sectional drawing. 同実施の形態１に係るラックバーの製造方法における素材準備工程を示す図であって、（ａ）は素材の断面図、（ｂ）は（ａ）のＡ−Ａ線による断面図である。It is a figure which shows the raw material preparation process in the manufacturing method of the rack bar which concerns on the same Embodiment 1, Comprising: (a) is sectional drawing of a raw material, (b) is sectional drawing by the AA line of (a). 同実施の形態１に係るラックバーの製造方法における歯形成部形成工程を示す素材の断面図である。It is sectional drawing of the raw material which shows the tooth | gear formation part formation process in the manufacturing method of the rack bar which concerns on the same Embodiment 1. FIG. 図５に示す歯形成部形成工程の詳細図であって、（ａ）は素材の断面図、（ｂ）は波形板状変形工程における（ａ）のＢ−Ｂ線による断面図、（ｃ）は平板状変形工程における（ａ）のＢ−Ｂ線による断面図である。It is detail drawing of the tooth | gear formation part formation process shown in FIG. 5, Comprising: (a) is sectional drawing of a raw material, (b) is sectional drawing by the BB line of (a) in a corrugated plate-shaped deformation | transformation process, (c). These are sectional drawings by the BB line of (a) in a flat deformation process. 図６に示す素材の拡大断面図であって、（ａ）は図６（ｂ）に対応する図、（ｂ）は図６（ｃ）に対応する図である。It is an expanded sectional view of the raw material shown in FIG. 6, Comprising: (a) is a figure corresponding to FIG.6 (b), (b) is a figure corresponding to FIG.6 (c). 同実施の形態１に係るラックバーの製造方法における歯形成工程を示す図であって、（ａ）は歯形成部にラック歯を形成する際の断面図、（ｂ）は第１歯形成工程における（ａ）のＣ−Ｃ線による断面図、（ｃ）は第２歯形成工程における（ａ）のＣ−Ｃ線による断面図である。It is a figure which shows the tooth | gear formation process in the manufacturing method of the rack bar which concerns on the same Embodiment 1, Comprising: (a) is sectional drawing at the time of forming a rack tooth in a tooth | gear formation part, (b) is a 1st tooth formation process. Sectional drawing by CC line of (a) in (a), (c) is sectional drawing by CC line of (a) in a 2nd tooth formation process. 本発明の実施の形態２に係るラックバーの製造方法における歯形成工程を示す図である。It is a figure which shows the tooth | gear formation process in the manufacturing method of the rack bar which concerns on Embodiment 2 of this invention.

以下、本発明の実施の形態について説明する。
［発明の実施の形態１］ Embodiments of the present invention will be described below.
Embodiment 1 of the Invention

図１乃至図８には、本発明の実施の形態１を示す。   1 to 8 show a first embodiment of the present invention.

自動車用のステアリング装置１は、図１に示すように、ステアリングホイール２の操作力（正逆回転力）を伝達する中間シャフト３を有しており、中間シャフト３にはピニオン軸５が連結されて回転自在に支持されている。ピニオン軸５にはラックバー６が、図２に示すように、ピニオン軸５の正逆回転運動をラックバー６の往復移動運動に変換しうるように連結されている。ラックバー６の両端にはそれぞれ、図１に示すように、前輪８を操舵するためのタイロッド７が連結されている。   As shown in FIG. 1, the automobile steering apparatus 1 includes an intermediate shaft 3 that transmits an operation force (forward / reverse rotational force) of the steering wheel 2, and a pinion shaft 5 is coupled to the intermediate shaft 3. And is supported rotatably. As shown in FIG. 2, the rack bar 6 is connected to the pinion shaft 5 so that the forward / reverse rotational motion of the pinion shaft 5 can be converted into the reciprocating motion of the rack bar 6. As shown in FIG. 1, tie rods 7 for steering the front wheels 8 are connected to both ends of the rack bar 6.

このピニオン軸５は、図２に示すように、ピニオン歯５ａを有している。   The pinion shaft 5 has pinion teeth 5a as shown in FIG.

また、ラックバー６は、図３に示すように、Ｄ形断面筒状の歯形成部１０を有しており、歯形成部１０の両側にはそれぞれ円筒状のバー本体１１が歯形成部１０に連通する形で一体に設けられている。歯形成部１０にはラック歯１２が形成されており、ラック歯１２は、図２に示すように、ピニオン軸５のピニオン歯５ａと噛み合っている。   Further, as shown in FIG. 3, the rack bar 6 has a D-shaped cylindrical tooth forming portion 10, and cylindrical bar bodies 11 are provided on both sides of the tooth forming portion 10, respectively. It is provided integrally in a form communicating with. Rack teeth 12 are formed in the tooth forming portion 10, and the rack teeth 12 mesh with the pinion teeth 5 a of the pinion shaft 5 as shown in FIG. 2.

このラック歯１２は、図３（ｃ）に示すように、バー本体１１の基準円ＳＣがピッチ平面ＰＰによって切り取られた弦の長さＬ２より広い歯幅Ｌ１を有している。ここで、基準円ＳＣとは、バー本体１１の外径に対応する仮想的な円である。また、ピッチ平面ＰＰとは、ラックバー６のラック歯１２がピニオン軸５のピニオン歯５ａと噛み合う仮想的な平面である。   As shown in FIG. 3C, the rack teeth 12 have a tooth width L1 that is wider than the length L2 of the chord in which the reference circle SC of the bar body 11 is cut by the pitch plane PP. Here, the reference circle SC is a virtual circle corresponding to the outer diameter of the bar body 11. The pitch plane PP is a virtual plane in which the rack teeth 12 of the rack bar 6 mesh with the pinion teeth 5a of the pinion shaft 5.

このように、ラックバー６は、全体が中空状であるため、中実状（丸棒状）の従来品に比べて、ラックバー６を軽量化することができる。しかも、ラック歯１２の歯幅Ｌ１は、バー本体１１の基準円ＳＣがピッチ平面ＰＰによって切り取られた弦の長さＬ２より広いので、このラックバー６と噛み合うピニオン軸５の歯元応力を減少させ、ピニオン歯５ａの耐久強度を高めることができる。   Thus, since the rack bar 6 is entirely hollow, the rack bar 6 can be reduced in weight compared to a solid (round bar-shaped) conventional product. In addition, the tooth width L1 of the rack tooth 12 is wider than the length L2 of the chord cut by the pitch plane PP of the reference circle SC of the bar body 11, so that the root stress of the pinion shaft 5 meshing with the rack bar 6 is reduced. The durability of the pinion teeth 5a can be increased.

また、このようなラックバー６を製造する際には、次の手順による。   Moreover, when manufacturing such a rack bar 6, it follows the following procedure.

まず、素材準備工程で、図４に示すように、円筒状の素材１３を準備する。   First, in the material preparation step, a cylindrical material 13 is prepared as shown in FIG.

こうして円筒状の素材１３が準備されたところで、歯形成部形成工程に移行し、図５に示すように、素材１３にＤ形断面筒状の歯形成部１０を２段階で形成する。それには、以下に詳述するとおり、まず波形板状変形工程で、素材１３の上部１３ａを波形板状に塑性変形させた後、平板状変形工程で、素材１３の上部１３ａを平板状に塑性変形させる。   When the cylindrical material 13 is thus prepared, the process proceeds to the tooth forming part forming step, and the D-shaped cylindrical tooth forming part 10 is formed on the material 13 in two stages as shown in FIG. For this purpose, as described in detail below, first, the upper portion 13a of the material 13 is plastically deformed into a corrugated plate shape in a corrugated plate deformation process, and then the upper portion 13a of the material 13 is plasticized into a flat plate shape in a flat plate deformation process. Deform.

すなわち、波形板状変形工程では、図６（ａ）、（ｂ）に示すように、下型１５の上面の溝１５ａに円筒状の素材１３を載置する。この溝１５ａは、素材１３の下部１３ｂにほぼ合致する半円形断面を呈しているため、素材１３の下部１３ｂは、その外周面が下型１５で支持された状態になる。   That is, in the corrugated plate deformation process, as shown in FIGS. 6A and 6B, the cylindrical material 13 is placed in the groove 15 a on the upper surface of the lower mold 15. Since the groove 15 a has a semicircular cross section that substantially matches the lower portion 13 b of the material 13, the outer peripheral surface of the lower portion 13 b of the material 13 is supported by the lower mold 15.

次いで、この素材１３の上側に上型１６を載置する。この上型１６は、素材１３の外径に等しい幅のパンチ挿入口１６ａが上下に貫通して形成された枠形状を有している。   Next, the upper mold 16 is placed on the upper side of the material 13. The upper die 16 has a frame shape in which a punch insertion port 16a having a width equal to the outer diameter of the material 13 is formed so as to penetrate vertically.

さらに、図６（ａ）に示すように、素材１３の中空部１３ｃに非対称の一対の心金１７、１８を素材１３の左右両端部から挿入する。一方の心金１７には、かまぼこ形の反力部１７ａおよび円環状の段部１７ｂが形成されている。この反力部１７ａは、図７に示すように、素材１３の内径（中空部１３ｃの直径）の半分にほぼ等しい曲率半径を有する曲面状（半円断面状）の下面１７ｃと、素材１３の内径より僅かに狭い幅を有する平坦な上面１７ｄとを備えている。他方の心金１８には、円環状の段部１８ｂが形成されている。そして、これらの心金１７、１８が素材１３の左右両端部から挿入されると、素材１３の下部１３ｂの内周面が心金１７の反力部１７ａの下面１７ｃに接触すると同時に、一対の心金１７、１８が歯形成部１０の端部近傍で互いに付き合わされ、さらに、心金１７、１８の段部１７ｂ、１８ｂが素材１３を左右両側から挟み込んだ状態になる。   Further, as shown in FIG. 6A, a pair of asymmetric cores 17 and 18 are inserted into the hollow portion 13 c of the material 13 from the left and right ends of the material 13. One mandrel 17 is formed with a kamaboko-shaped reaction force portion 17a and an annular step portion 17b. As shown in FIG. 7, the reaction force portion 17 a includes a curved lower surface 17 c having a radius of curvature substantially equal to half of the inner diameter of the material 13 (diameter of the hollow portion 13 c), and the material 13. And a flat upper surface 17d having a width slightly narrower than the inner diameter. The other mandrel 18 is formed with an annular step 18b. When these cores 17 and 18 are inserted from both left and right ends of the material 13, the inner peripheral surface of the lower part 13 b of the material 13 comes into contact with the lower surface 17 c of the reaction force part 17 a of the core 17, and a pair of The mandrels 17 and 18 are brought into contact with each other in the vicinity of the end portion of the tooth forming portion 10, and the step portions 17b and 18b of the mandrel 17 and 18 sandwich the material 13 from the left and right sides.

その後、図６（ａ）、（ｂ）に示すように、上型１６のパンチ挿入口１６ａに波形板状成形パンチ２０を挿入して素材１３の上部１３ａを下向きに強く押圧する。この波形板状成形パンチ２０の下部には、図７（ａ）に示すように、２条の凸部２０ｂが下向きに設けられた押圧面２０ａが形成されている。   Thereafter, as shown in FIGS. 6A and 6B, the corrugated plate-shaped forming punch 20 is inserted into the punch insertion opening 16 a of the upper mold 16 and the upper portion 13 a of the material 13 is strongly pressed downward. As shown in FIG. 7 (a), a pressing surface 20a in which two protruding portions 20b are provided downward is formed at the lower portion of the corrugated plate forming punch 20.

すると、素材１３の上部１３ａは、図６（ｂ）および図７（ａ）に示すように、２つの凹部１３ｄを有する波形板状に塑性変形する。   Then, as shown in FIGS. 6B and 7A, the upper portion 13a of the material 13 is plastically deformed into a corrugated plate shape having two recesses 13d.

このとき、上型１６のパンチ挿入口１６ａは、上述したとおり、素材１３の外径に等しい幅となっているため、素材１３の上部１３ａは、バー本体１１の基準円ＳＣの外側に膨らむように平板状に塑性変形する。また、素材１３の中空部１３ｃに挿入された一対の心金１７、１８が歯形成部１０の端部近傍、つまり歯形成部１０の中央部近傍でない部位で互いに付き合わされているため、この塑性変形を素材１３の長さ方向に沿って均一に実施することができる。しかも、素材１３は心金１７、１８の段部１７ｂ、１８ｂによって左右両側から挟み込まれているので、素材１３の長さ方向の移動を拘束して適正な部位を塑性変形させることができる。さらに、素材１３の下部１３ｂは、上述したとおり、外周面が下型１５で支持されると同時に、内周面が心金１７の反力部１７ａの下面１７ｃに接触した状態を維持しているため、この塑性変形に伴って素材１３の上部１３ａの材料が下部１３ｂへ移動することは起こらない。   At this time, since the punch insertion opening 16a of the upper die 16 has a width equal to the outer diameter of the material 13, as described above, the upper portion 13a of the material 13 swells outside the reference circle SC of the bar body 11. It is plastically deformed into a flat plate shape. Further, since the pair of mandrels 17 and 18 inserted into the hollow portion 13c of the material 13 are attached to each other in the vicinity of the end portion of the tooth forming portion 10, that is, the portion not near the center portion of the tooth forming portion 10, this plasticity The deformation can be performed uniformly along the length direction of the material 13. In addition, since the material 13 is sandwiched from the left and right sides by the step portions 17b and 18b of the cores 17 and 18, it is possible to restrain the movement of the material 13 in the length direction and plastically deform an appropriate part. Furthermore, as described above, the lower surface 13b of the material 13 is supported by the lower mold 15 and at the same time the inner peripheral surface is in contact with the lower surface 17c of the reaction force portion 17a of the mandrel 17. Therefore, the material of the upper part 13a of the raw material 13 does not move to the lower part 13b with this plastic deformation.

また、平板状変形工程では、波形板状成形パンチ２０を上型１６から抜き取った後、図６（ａ）、（ｃ）に示すように、平板状成形パンチ２１を上型１６のパンチ挿入口１６ａに挿入して素材１３の上部１３ａを下向きに強く押圧する。この平板状成形パンチ２１の下部には、図７（ｂ）に示すように、平面状の押圧面２１ａが形成されている。なお、本来であれば、波形板状変形工程における断面図と平板状変形工程における断面図とを別個の２図面で示すべきであるが、両者は波形板状成形パンチ２０と平板状成形パンチ２１との違いしか存在しないため、便宜上、これらの２図面を１図面（図６（ａ））で簡略的に示している。   In the flat plate deformation step, after the corrugated plate forming punch 20 is extracted from the upper die 16, the flat plate forming punch 21 is inserted into the punch insertion opening of the upper die 16 as shown in FIGS. It inserts in 16a and strongly presses the upper part 13a of the raw material 13 downward. As shown in FIG. 7B, a flat pressing surface 21a is formed below the flat plate forming punch 21. As shown in FIG. In addition, originally, the cross-sectional view in the corrugated plate deformation step and the cross-sectional view in the flat plate deformation step should be shown in two separate drawings, both of which are the corrugated plate forming punch 20 and the flat plate forming punch 21. These two drawings are simply shown in one drawing (FIG. 6A) for convenience.

すると、素材１３の上部１３ａは、図６（ｃ）および図７（ｂ）に示すように、平板状に塑性変形する。   Then, as shown in FIGS. 6C and 7B, the upper portion 13a of the material 13 is plastically deformed into a flat plate shape.

このときも、波形板状変形工程と同様、素材１３の中空部１３ｃに挿入された一対の心金１７、１８が歯形成部１０の端部近傍、つまり歯形成部１０の中央部近傍でない部位で互いに付き合わされているため、この塑性変形を素材１３の長さ方向に沿って均一に実施することができる。しかも、素材１３は心金１７、１８の段部１７ｂ、１８ｂによって左右両側から挟み込まれているので、素材１３の長さ方向の移動を拘束して適正な部位を塑性変形させることができる。また、素材１３の下部１３ｂは、外周面が下型１５で支持されると同時に、内周面が心金１７の反力部１７ａの下面１７ｃに接触した状態を維持しているため、この塑性変形に伴って素材１３の上部１３ａの材料が下部１３ｂへ移動することは起こらない。したがって、図７（ｂ）に示すように、素材１３の下部１３ｂの曲率中心Ｏより少し上側の位置で素材１３の上部１３ａが平板状に塑性変形するように平板状成形パンチ２１の押圧力を適宜調整することにより、平板状の上部１３ａの肉厚ｔ１を下部１３ｂの肉厚ｔ２より厚くすることが可能となる。そのため、後述する歯形成工程において、ラック歯１２を形成するための材料を確保することができる。   At this time, similarly to the corrugated plate deformation process, the pair of mandrels 17 and 18 inserted into the hollow portion 13c of the material 13 is not near the end of the tooth forming portion 10, that is, near the center of the tooth forming portion 10. Therefore, this plastic deformation can be carried out uniformly along the length direction of the material 13. In addition, since the material 13 is sandwiched from the left and right sides by the step portions 17b and 18b of the cores 17 and 18, it is possible to restrain the movement of the material 13 in the length direction and plastically deform an appropriate part. Further, the lower portion 13b of the material 13 is supported by the lower mold 15 and at the same time the inner peripheral surface is kept in contact with the lower surface 17c of the reaction force portion 17a of the mandrel 17. The material of the upper part 13a of the raw material 13 does not move to the lower part 13b with the deformation. Therefore, as shown in FIG. 7B, the pressing force of the flat plate forming punch 21 is set so that the upper portion 13a of the raw material 13 is plastically deformed into a flat plate shape at a position slightly above the center of curvature O of the lower portion 13b of the raw material 13. By adjusting appropriately, it becomes possible to make thickness t1 of flat upper part 13a thicker than thickness t2 of lower part 13b. Therefore, a material for forming the rack teeth 12 can be ensured in a tooth forming process described later.

その結果、図５に示すように、素材１３にＤ形断面筒状の歯形成部１０が形成される。   As a result, as shown in FIG. 5, the tooth forming portion 10 having a D-shaped cross-section cylindrical shape is formed on the material 13.

このようにして、素材１３に歯形成部１０が形成されるとともに、この歯形成部１０以外の部位に円筒状のバー本体１１が形成される。   In this way, the tooth forming portion 10 is formed on the material 13 and the cylindrical bar body 11 is formed at a portion other than the tooth forming portion 10.

こうして素材１３に歯形成部１０およびバー本体１１が形成されたところで、歯形成工程に移行し、図８に示すように、２種類の歯形成パンチ（第１歯形成パンチ２２および第２歯形成パンチ２３）を用いて歯形成部１０にラック歯１２を２段階で形成する。なお、図８（ａ）においては、下型１５、上型１６および心金１７、１８の図示を省略している。   When the tooth forming portion 10 and the bar main body 11 are thus formed on the material 13, the process proceeds to the tooth forming process, and as shown in FIG. 8, two types of tooth forming punches (first tooth forming punch 22 and second tooth forming) are formed. Using the punch 23), the rack teeth 12 are formed on the tooth forming portion 10 in two stages. In FIG. 8A, illustration of the lower die 15, the upper die 16, and the cores 17 and 18 is omitted.

それには、まず第１歯形成工程で、平板状成形パンチ２１を上型１６から抜き取った後、図８（ｂ）に示すように、第１歯形成パンチ２２を上型１６のパンチ挿入口１６ａに挿入して歯形成部１０を下向きに強く押圧することにより、所望の高さの半分程度の高さ・深さの山と谷を形成する。続けて、第２歯形成工程で、第１歯形成パンチ２２を上型１６から抜き取った後、図８（ｃ）に示すように、第２歯形成パンチ２３を上型１６のパンチ挿入口１６ａに挿入して歯形成部１０を下向きに強く押圧することにより、所望の高さ・深さの山と谷を形成する。   For this purpose, first, in the first tooth forming step, the flat plate forming punch 21 is extracted from the upper die 16, and then the first tooth forming punch 22 is inserted into the punch insertion port 16a of the upper die 16 as shown in FIG. By inserting the tooth forming portion 10 and pressing the tooth forming portion 10 downward strongly, peaks and valleys having a height and a depth of about half of the desired height are formed. Subsequently, after the first tooth forming punch 22 is extracted from the upper die 16 in the second tooth forming step, the second tooth forming punch 23 is inserted into the punch insertion port 16a of the upper die 16 as shown in FIG. Then, the tooth forming part 10 is strongly pressed downward to form peaks and valleys having a desired height and depth.

すると、図８（ａ）に示すように、歯形成部１０にラック歯１２が形成される。   Then, as shown in FIG. 8A, rack teeth 12 are formed on the tooth forming portion 10.

このとき、歯形成部１０は、バー本体１１の直径と同程度の幅を有しているので、十分な歯幅Ｌ１のラック歯１２を形成することができる。したがって、このラックバー６と噛み合うピニオン軸５の歯元応力を減少させ、ピニオン歯５ａの耐久強度を高めることができる。加えて、上述したとおり、直前の波形板状変形工程において、素材１３の平板状の上部１３ａにラック歯１２を形成するための材料が確保されているので、十分な肉厚でラック歯１２を形成することができる。また、素材１３の中空部１３ｃに挿入された一対の心金１７、１８が歯形成部１０の端部近傍、つまり歯形成部１０の中央部近傍でない部位で互いに付き合わされているため、このラック歯１２の形成を素材１３の長さ方向に沿って均一に実施することができる。しかも、素材１３は心金１７、１８の段部１７ｂ、１８ｂによって左右両側から挟み込まれているので、素材１３の長さ方向の移動を拘束して適正な部位にラック歯１２を形成することができる。   At this time, since the tooth forming portion 10 has a width approximately equal to the diameter of the bar body 11, the rack teeth 12 having a sufficient tooth width L1 can be formed. Therefore, the root stress of the pinion shaft 5 meshing with the rack bar 6 can be reduced, and the durability of the pinion teeth 5a can be increased. In addition, as described above, since the material for forming the rack teeth 12 on the flat upper portion 13a of the material 13 is secured in the immediately preceding corrugated plate deformation step, the rack teeth 12 are formed with a sufficient thickness. Can be formed. Further, since the pair of mandrels 17 and 18 inserted into the hollow portion 13c of the material 13 are attached to each other in the vicinity of the end portion of the tooth forming portion 10, that is, the portion not near the center portion of the tooth forming portion 10, this rack The teeth 12 can be formed uniformly along the length direction of the material 13. In addition, since the material 13 is sandwiched from the left and right sides by the step portions 17b and 18b of the cores 17 and 18, the rack teeth 12 can be formed at appropriate portions by restraining the movement of the material 13 in the length direction. it can.

こうして素材１３の上部１３ａにラック歯１２が形成されたところで、心金離脱工程に移行し、心金１７、１８を素材１３の中空部１３ｃから取り外して離脱させる。   Thus, when the rack teeth 12 are formed on the upper portion 13a of the material 13, the process proceeds to a mandrel detachment process, and the mandrels 17 and 18 are detached from the hollow portion 13c of the material 13 and separated.

ここで、ラックバー６の製造が終了し、ラックバー６が完成する。   Here, the production of the rack bar 6 is completed, and the rack bar 6 is completed.

このように、ラックバー６の製造に際しては、所定の下型１５、上型１６、心金１７、１８、波形板状成形パンチ２０、平板状成形パンチ２１、第１歯形成パンチ２２および第２歯形成パンチ２３を用いて、素材１３の上部１３ａを波形板状に塑性変形させてから平板状に塑性変形させた後、この部位にラック歯１２を形成するようにした。その結果、ラック歯１２の肉厚および歯幅を確保することが可能となる。
［発明の実施の形態２］ As described above, when the rack bar 6 is manufactured, the predetermined lower die 15, upper die 16, core bars 17 and 18, corrugated plate-shaped forming punch 20, flat plate-shaped forming punch 21, first tooth forming punch 22, and second Using the tooth forming punch 23, the upper portion 13a of the material 13 was plastically deformed into a corrugated plate shape and then plastically deformed into a flat plate shape, and then the rack teeth 12 were formed at this portion. As a result, it is possible to ensure the thickness and tooth width of the rack teeth 12.
[Embodiment 2 of the Invention]

図９には、本発明の実施の形態２を示す。   FIG. 9 shows a second embodiment of the present invention.

この実施の形態２では、歯形成工程において、歯形成パンチ２２、２３を用いてラック歯１２を鍛造する代わりに、図９に示すように、大小２種類の転写ローラ２５を歯形成部１０上で転動させてラック歯１２を形成する点を除き、上述した実施の形態１と同じ構成を有している。なお、実施の形態１と同一の部材については、同一の符号を付してその説明を省略する。   In the second embodiment, instead of forging the rack teeth 12 using the tooth forming punches 22 and 23 in the tooth forming step, two kinds of large and small transfer rollers 25 are provided on the tooth forming portion 10 as shown in FIG. The configuration is the same as that of the first embodiment except that the rack teeth 12 are formed by rolling. In addition, about the member same as Embodiment 1, the same code | symbol is attached | subjected and the description is abbreviate | omitted.

このとき、転写ローラ２５は必ずしも大小２種類を用いる必要はなく、１種類の転写ローラ２５だけでラック歯１２を転動することも勿論できる。
［発明のその他の実施の形態］ At this time, it is not always necessary to use two kinds of transfer rollers 25, and the rack teeth 12 can be rolled by only one kind of transfer roller 25.
[Other Embodiments of the Invention]

なお、上述した実施の形態１、２では、上型１６のパンチ挿入口１６ａの幅が素材１３の外径に等しい場合について説明した。しかし、素材１３の外径より広い幅のパンチ挿入口１６ａを有する上型１６を代用することもできる。   In the first and second embodiments, the case where the width of the punch insertion opening 16a of the upper die 16 is equal to the outer diameter of the material 13 has been described. However, the upper die 16 having a punch insertion opening 16a having a width wider than the outer diameter of the material 13 can be substituted.

また、上述した実施の形態１、２では、２条の凸部２０ｂが形成された押圧面２０ａを有する波形板状成形パンチ２０を用いる場合について説明した。しかし、凸部２０ｂの条数は２つに限るわけではなく、複数であれば何条でも構わない。   Moreover, Embodiment 1 and 2 mentioned above demonstrated the case where the corrugated plate-shaped shaping | molding punch 20 which has the press surface 20a in which the two convex parts 20b were formed was used. However, the number of protrusions 20b is not limited to two, and any number of protrusions 20b may be used.

本発明は、自動車用のステアリング装置など各種の装置・機器に幅広く適用することができる。   The present invention can be widely applied to various devices and devices such as a steering device for automobiles.

１……ステアリング装置
２……ステアリングホイール
３……中間シャフト
５……ピニオン軸
５ａ……ピニオン歯
６……ラックバー
７……タイロッド
８……前輪
１０……歯形成部
１１……バー本体
１２……ラック歯
１３……素材
１３ａ……上部
１３ｂ……下部
１３ｃ……中空部
１３ｄ……凹部
１５……下型
１５ａ……溝
１６……上型
１６ａ……パンチ挿入口
１７、１８……心金
１７ａ……反力部
１７ｂ、１８ｂ……段部
１７ｃ……下面
１７ｄ……上面
２０……波形板状成形パンチ
２０ａ……押圧面
２０ｂ……凸部
２１……平板状成形パンチ
２１ａ……押圧面
２２……第１歯形成パンチ
２３……第２歯形成パンチ
２５……転写ローラ
Ｌ１……ラック歯の歯幅
Ｌ２……弦の長さ
ＰＰ……ピッチ平面
ＳＣ……基準円
ｔ１……素材の上部の肉厚
ｔ２……素材の下部の肉厚 DESCRIPTION OF SYMBOLS 1 ... Steering device 2 ... Steering wheel 3 ... Intermediate shaft 5 ... Pinion shaft 5a ... Pinion tooth 6 ... Rack bar 7 ... Tie rod 8 ... Front wheel 10 ... Tooth formation part 11 ... Bar main body 12 ...... Rack teeth 13 …… Material 13a …… Upper 13b …… Lower 13c …… Hollow 13d …… Recess 15 …… Lower mold 15a …… Groove 16 …… Upper mold 16a …… Punch insertion slot 17, 18 …… Mandrel 17a ... Reaction force part 17b, 18b ... Step part 17c ... Bottom face 17d ... Top face 20 ... Corrugated plate forming punch 20a ... Pressing surface 20b ... Convex part 21 ... Flat plate forming punch 21a ... ... Pressing surface 22 …… First tooth forming punch 23 …… Second tooth forming punch 25 …… Transfer roller L1 …… Rack tooth width L2 …… String length PP …… Pitch plane SC …… Reference circle t1 ...... Thickness at the top of the material t2 …… Thickness at the bottom of the material

Claims (7)

自動車用のステアリング装置に使用され、所定の基準円に対応する外径を有する円筒状のバー本体と、ピッチ平面に沿って形成されたラック歯とを備え、前記ラック歯の歯幅は、前記基準円が前記ピッチ平面によって切り取られた弦の長さより広いラックバーであって、
円筒状の素材の下部が下型で支持されるとともに、前記素材の外径以上の幅のパンチ挿入口が形成された上型で当該素材の上部が支持され、さらに、前記素材の中空部に心金が挿入されて当該素材の下部に接触した状態で、波形板状成形パンチを前記パンチ挿入口に挿入して前記素材の上部を押圧することにより、前記素材の上部を波形板状に塑性変形させる波形板状変形工程と、
前記波形板状成形パンチに代えて平板状成形パンチを前記パンチ挿入口に挿入して前記素材の上部を押圧することにより、前記素材の上部を平板状に塑性変形させる平板状変形工程と、
前記素材の上部にラック歯を形成する歯形成工程と
を含む製造方法によって製造されたことを特徴とするラックバー。 A cylindrical bar body that is used in a steering device for an automobile and has an outer diameter corresponding to a predetermined reference circle, and rack teeth formed along a pitch plane, and the tooth width of the rack teeth is: A rack bar whose reference circle is wider than the length of the string cut by the pitch plane ;
The lower part of the cylindrical material is supported by the lower mold, the upper part of the material is supported by the upper mold in which a punch insertion opening having a width equal to or larger than the outer diameter of the material is formed, and the hollow part of the material is further supported. With the mandrel inserted and in contact with the lower part of the material, a corrugated plate-shaped forming punch is inserted into the punch insertion port and the upper part of the material is pressed to plasticize the upper part of the material into a corrugated plate shape. A corrugated plate-shaped deformation process to be deformed;
A flat plate-shaped deformation step of plastically deforming the upper portion of the material into a flat plate shape by inserting a flat plate-shaped forming punch into the punch insertion port instead of the corrugated plate-shaped forming punch, and pressing the upper portion of the material.
A tooth forming step of forming rack teeth on the top of the material;
A rack bar manufactured by a manufacturing method including: 前記ラック歯の歯幅は、前記バー本体の外径に一致していることを特徴とする請求項１に記載のラックバー。   The rack bar according to claim 1, wherein a tooth width of the rack tooth coincides with an outer diameter of the bar main body. 円筒状の素材の下部が下型で支持されるとともに、前記素材の外径以上の幅のパンチ挿入口が形成された上型で当該素材の上部が支持され、さらに、前記素材の中空部に心金が挿入されて当該素材の下部に接触した状態で、波形板状成形パンチを前記パンチ挿入口に挿入して前記素材の上部を押圧することにより、前記素材の上部を波形板状に塑性変形させる波形板状変形工程と、
前記波形板状成形パンチに代えて平板状成形パンチを前記パンチ挿入口に挿入して前記素材の上部を押圧することにより、前記素材の上部を平板状に塑性変形させる平板状変形工程と、
前記素材の上部にラック歯を形成する歯形成工程と
を含むことを特徴とするラックバーの製造方法。 The lower part of the cylindrical material is supported by the lower mold, the upper part of the material is supported by the upper mold in which a punch insertion opening having a width equal to or larger than the outer diameter of the material is formed, and the hollow part of the material is further supported. With the mandrel inserted and in contact with the lower part of the material, a corrugated plate-shaped forming punch is inserted into the punch insertion port and the upper part of the material is pressed to plasticize the upper part of the material into a corrugated plate shape. A corrugated plate-shaped deformation process to be deformed;
A flat plate-shaped deformation step of plastically deforming the upper portion of the material into a flat plate shape by inserting a flat plate-shaped forming punch into the punch insertion port instead of the corrugated plate-shaped forming punch, and pressing the upper portion of the material.
And a tooth forming step of forming rack teeth on the upper portion of the material. 前記波形板状変形工程において、前記波形板状成形パンチとして、複数の凸部が形成された押圧面を有するものを用いることにより、前記素材の上部に複数の凹部を形成して波形板状に塑性変形させることを特徴とする請求項３に記載のラックバーの製造方法。   In the corrugated plate deformation step, by using a corrugated plate forming punch having a pressing surface on which a plurality of convex portions are formed, a plurality of concave portions are formed on the top of the material to form a corrugated plate shape. The method of manufacturing a rack bar according to claim 3, wherein the rack bar is plastically deformed. 前記平板状変形工程において、前記素材の上部を平板状に塑性変形させる際に当該素材の上部の肉厚を当該素材の下部の肉厚より厚くすることを特徴とする請求項３または４に記載のラックバーの製造方法。   5. The thickness of the upper part of the material is made thicker than the thickness of the lower part of the material when the upper part of the material is plastically deformed into a flat plate shape in the flat plate deformation step. Rack bar manufacturing method. 前記歯形成工程において、前記平板状成形パンチに代えて歯形成パンチを前記パンチ挿入口に挿入して前記素材の上部を押圧することにより、前記素材の上部にラック歯を形成することを特徴とする請求項３乃至５のいずれかに記載のラックバーの製造方法。   In the tooth forming step, a rack tooth is formed on the upper portion of the material by inserting a tooth forming punch into the punch insertion opening instead of the flat plate forming punch and pressing the upper portion of the material. The method for manufacturing a rack bar according to any one of claims 3 to 5. 前記心金は、前記素材のラック歯を形成する部位に対向する反力部が、かまぼこ形を呈し、前記素材の内径の半分にほぼ等しい曲率半径を有する曲面状の下面と、前記素材の内径より僅かに狭い幅を有する平坦な上面とを備えることを特徴とする請求項３乃至６のいずれかに記載のラックバーの製造方法。   The mandrel has a curved bottom surface in which the reaction force portion facing the portion forming the rack teeth of the material has a kamaboko shape and has a radius of curvature substantially equal to half of the inner diameter of the material, and the inner diameter of the material The method of manufacturing a rack bar according to any one of claims 3 to 6, further comprising a flat upper surface having a slightly narrower width.
JP2011014136A 2011-01-26 2011-01-26 Rack bar and manufacturing method thereof Expired - Fee Related JP5496926B2 (en)

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