JP6366977B2 - 等速自在継手の外側継手部材の製造方法および外側継手部材 - Google Patents
等速自在継手の外側継手部材の製造方法および外側継手部材 Download PDFInfo
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- JP6366977B2 JP6366977B2 JP2014068408A JP2014068408A JP6366977B2 JP 6366977 B2 JP6366977 B2 JP 6366977B2 JP 2014068408 A JP2014068408 A JP 2014068408A JP 2014068408 A JP2014068408 A JP 2014068408A JP 6366977 B2 JP6366977 B2 JP 6366977B2
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- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
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- F16D3/16—Universal joints in which flexibility is produced by means of pivots or sliding or rolling connecting parts
- F16D3/20—Universal joints in which flexibility is produced by means of pivots or sliding or rolling connecting parts one coupling part entering a sleeve of the other coupling part and connected thereto by sliding or rolling members
- F16D3/22—Universal joints in which flexibility is produced by means of pivots or sliding or rolling connecting parts one coupling part entering a sleeve of the other coupling part and connected thereto by sliding or rolling members the rolling members being balls, rollers, or the like, guided in grooves or sockets in both coupling parts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
- B21K1/00—Making machine elements
- B21K1/76—Making machine elements elements not mentioned in one of the preceding groups
- B21K1/762—Coupling members for conveying mechanical motion, e.g. universal joints
- B21K1/765—Outer elements of coupling members
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K15/00—Electron-beam welding or cutting
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
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- B23K15/0046—Welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
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- B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to investigating the properties, e.g. the weldability, of materials
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- F16D1/00—Couplings for rigidly connecting two coaxial shafts or other movable machine elements
- F16D1/02—Couplings for rigidly connecting two coaxial shafts or other movable machine elements for connecting two abutting shafts or the like
- F16D1/027—Couplings for rigidly connecting two coaxial shafts or other movable machine elements for connecting two abutting shafts or the like non-disconnectable, e.g. involving gluing, welding or the like
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- F16D1/00—Couplings for rigidly connecting two coaxial shafts or other movable machine elements
- F16D1/06—Couplings for rigidly connecting two coaxial shafts or other movable machine elements for attachment of a member on a shaft or on a shaft-end
- F16D1/064—Couplings for rigidly connecting two coaxial shafts or other movable machine elements for attachment of a member on a shaft or on a shaft-end non-disconnectable
- F16D1/068—Couplings for rigidly connecting two coaxial shafts or other movable machine elements for attachment of a member on a shaft or on a shaft-end non-disconnectable involving gluing, welding or the like
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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- F16D3/20—Universal joints in which flexibility is produced by means of pivots or sliding or rolling connecting parts one coupling part entering a sleeve of the other coupling part and connected thereto by sliding or rolling members
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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- F16D3/223—Universal joints in which flexibility is produced by means of pivots or sliding or rolling connecting parts one coupling part entering a sleeve of the other coupling part and connected thereto by sliding or rolling members the rolling members being balls, rollers, or the like, guided in grooves or sockets in both coupling parts the rolling members being guided in grooves in both coupling parts
- F16D3/226—Universal joints in which flexibility is produced by means of pivots or sliding or rolling connecting parts one coupling part entering a sleeve of the other coupling part and connected thereto by sliding or rolling members the rolling members being balls, rollers, or the like, guided in grooves or sockets in both coupling parts the rolling members being guided in grooves in both coupling parts the groove centre-lines in each coupling part lying on a cylinder co-axial with the respective coupling part
- F16D3/227—Universal joints in which flexibility is produced by means of pivots or sliding or rolling connecting parts one coupling part entering a sleeve of the other coupling part and connected thereto by sliding or rolling members the rolling members being balls, rollers, or the like, guided in grooves or sockets in both coupling parts the rolling members being guided in grooves in both coupling parts the groove centre-lines in each coupling part lying on a cylinder co-axial with the respective coupling part the joints being telescopic
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D3/00—Yielding couplings, i.e. with means permitting movement between the connected parts during the drive
- F16D3/16—Universal joints in which flexibility is produced by means of pivots or sliding or rolling connecting parts
- F16D3/20—Universal joints in which flexibility is produced by means of pivots or sliding or rolling connecting parts one coupling part entering a sleeve of the other coupling part and connected thereto by sliding or rolling members
- F16D3/22—Universal joints in which flexibility is produced by means of pivots or sliding or rolling connecting parts one coupling part entering a sleeve of the other coupling part and connected thereto by sliding or rolling members the rolling members being balls, rollers, or the like, guided in grooves or sockets in both coupling parts
- F16D3/223—Universal joints in which flexibility is produced by means of pivots or sliding or rolling connecting parts one coupling part entering a sleeve of the other coupling part and connected thereto by sliding or rolling members the rolling members being balls, rollers, or the like, guided in grooves or sockets in both coupling parts the rolling members being guided in grooves in both coupling parts
- F16D2003/22326—Attachments to the outer joint member, i.e. attachments to the exterior of the outer joint member or to the shaft of the outer joint member
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D3/00—Yielding couplings, i.e. with means permitting movement between the connected parts during the drive
- F16D3/16—Universal joints in which flexibility is produced by means of pivots or sliding or rolling connecting parts
- F16D3/20—Universal joints in which flexibility is produced by means of pivots or sliding or rolling connecting parts one coupling part entering a sleeve of the other coupling part and connected thereto by sliding or rolling members
- F16D3/202—Universal joints in which flexibility is produced by means of pivots or sliding or rolling connecting parts one coupling part entering a sleeve of the other coupling part and connected thereto by sliding or rolling members one coupling part having radially projecting pins, e.g. tripod joints
- F16D3/205—Universal joints in which flexibility is produced by means of pivots or sliding or rolling connecting parts one coupling part entering a sleeve of the other coupling part and connected thereto by sliding or rolling members one coupling part having radially projecting pins, e.g. tripod joints the pins extending radially outwardly from the coupling part
- F16D3/2055—Universal joints in which flexibility is produced by means of pivots or sliding or rolling connecting parts one coupling part entering a sleeve of the other coupling part and connected thereto by sliding or rolling members one coupling part having radially projecting pins, e.g. tripod joints the pins extending radially outwardly from the coupling part having three pins, i.e. true tripod joints
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- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
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Description
バー材)を鍛造加工やしごき加工等の塑性加工、切削加工、熱処理、研削加工等を施すことによって、カップ部と軸部とを一体成形する場合が多い。
(1)生産技術の面では、カップ部材と軸部材を密閉空間に設置して真空引きし、中空空洞部も真空化された状態で溶接することで溶融物の吹き上がりや気泡の発生が抑えられる。
(2)また、生産性の面では、生産性向上を図るために焼入れ焼戻しの熱処理を施したカップ部材と軸部材を溶接する場合、溶接時の熱で周辺部の温度が上昇し、熱処理部の硬度が低下する懸念がある。この問題に対しては、溶接工程の順序の入れ替えにより、継手機能への影響がない範囲で最も効率的でコスト低減が可能な工程で接合するという方法に着目した。例えば、溶接時の熱影響がないものであれば、焼入れ焼戻しの熱処理を施した完成状態のカップ部材と軸部材を溶接し、一方、熱影響があるものは、溶接後の熱処理とする工程とするなど、カップ部材や軸部材の形状、仕様等に応じて最適な工程をとるコンセプトを見出した。
(3)さらに、生産性や品種統合の面では、図23〜25に示すカップ部材72には、次のような問題があることが判明した。すなわち、カップ部材72は、鍛造加工等によりカップ部の底部より縮径された短軸部が形成されるが、この短軸部が軸部材73の形状、寸法を基準にして設定され、軸部の途中位置で接合される構成となっている。軸部材73は、組み付けられる車両によって、標準的な長さのステムやロングステムというタイプの違いに加えて、種々の軸径や外周形状が要求される。このため、カップ部材72の短軸部を軸部材73の形状、寸法を基準にして設定し、軸部の途中位置で接合する場合、軸部材73と接合されるカップ部材72の短軸部の軸径(接合径)や形状、長さ(接合位置)の両方が異なるため、一種類の軸部材73に対して専用のカップ部材72が必要になる。したがって、生産性の向上やカップ部材の品種統合によるコスト低減の面でも問題があることが判明した。
(4)加えて、自動車用等の量産製品である等速自在継手の外側継手部材の新たな製造コンセプトを実用面で成立させるためには、溶接部の検査精度および検査作業性の向上を可能にする超音波探傷検査の方法や溶接部形状に工夫が必要であることが判明した。
鍛造重量に基づいてバー材を所定長さで切断し、ビレットを製作する。
ビレットを鍛造加工により、カップ部材12aの素形材として筒状部、底部および凸部を一体成形する。
前記素形材のトラック溝30および筒状円筒面42をしごき加工して、カップ部材12aの筒状部の内周を仕上げる。
しごき加工後の素形材に、外周面、ブーツ取付溝32、止め輪溝33などと接合用端面50を旋削加工する。本実施形態では、旋削加工工程S4cの後、中間部品としてのカップ部材12aに品番を付与して管理する。
[バー材切断工程S1s]
軸部全長に基づいてバー材を所定長さで切断し、ビレットを製作する。その後、軸部材13aの形状に応じて、ビレットをアプセット鍛造により概略形状に鍛造加工する場合もある。
ビレットの外周面(軸受装着面14、止め輪溝15、スプライン下径、端面など)とカップ部材12a側端部の接合用端面51を旋削加工する。
旋削加工後の軸部材にスプラインを転造加工する。ただし、スプラインの加工は転造加工に限られるものではなく、適宜プレス加工等に置き換えることもできる。本実施形態では、スプライン加工後、中間部品としての軸部材13aに品番を付与して管理する。
カップ部材12aの接合用端面50と軸部材13aの接合用端面51を突合せて溶接する。
カップ部材12aと軸部材13aの溶接部49を超音波探傷方法により検査する。
溶接後のカップ部12の少なくともトラック溝30、筒状内周面42および軸部13の外周の必要範囲に熱処理として高周波焼入れ焼戻しを行う。溶接部は熱処理を施さない。カップ部12のトラック溝30や筒状内周面42はHRC58〜62程度の硬化層が形成される。また、軸部13の外周の所定範囲にHRC50〜62程度の硬化層が形成される。
熱処理後、軸部13の軸受装着面14等を研削加工して仕上げる。これにより、外側継手部材11が完成する。
2 中間シャフト
3 スプライン
4 ブーツ
5 ブーツ
6 サポートベアリング
10 摺動式等速自在継手
11 外側継手部材
12 カップ部
12a カップ部材
12a1 筒状部
12a2 底部
13 長寸軸部
13a 軸部材
14 軸受装着面
16 内側継手部材
17 トリポード部材
19 トルク伝達要素(ローラ)
20 固定式等速自在継手
21 外側継手部材
22 内側継手部材
23 トルク伝達要素(ボール)
24 保持器
30 トラック溝
31 内周面
40 トラック溝
41 トルク伝達要素(ボール)
42 筒状内周面
49 溶接部
50 接合用端面
50a 突出面
51 接合用端面
52 凹部
100 溶接装置
101 電子銃
108 ケース
109 真空ポンプ
111 密閉空間
120 超音波探傷検査装置
121 基台
122 貯水槽
123 ワーク受台
124 ワーク押え部材
125 回転駆動装置
135 押圧装置
136 探触子の駆動位置決め装置
147 探触子
B 外径
D 内径
E 内径
G 送信パルス
R 反射エコー
O 継手中心
O1 曲率中心
O2 曲率中心
Sp スプライン
Claims (8)
- トルク伝達要素が係合するトラック溝を内周に形成したカップ部と、このカップ部の底部に形成された軸部とを別部材で構成し、前記カップ部を形成するカップ部材と前記軸部を形成する軸部材とを溶接してなる等速自在継手の外側継手部材の製造方法において、
前記カップ部材と軸部材を中炭素鋼で形成し、前記カップ部材として、その筒状部と底部を鍛造加工により一体に形成した後、機械加工工程において前記底部の外面に接合用端面を形成したカップ部材を準備し、前記軸部材として、機械加工工程において前記カップ部材の底部と接合される接合用端面を形成した軸部材を準備し、前記カップ部材の接合用端面と軸部材の接合用端面を突合せて、この突合せ部に前記カップ部材の外側から半径方向にビームを照射して溶接するものであって、前記軸部材は、サポートベアリングの軸受装着面を含めて、前記軸部材が組み込まれる車種に応じた特有の仕様を有し、前記等速自在継手の形式および前記軸部材の特定の仕様に関係なく、前記カップ部材の接合用端面の外径をジョイントサイズ毎に同一寸法とし、前記カップ部材と軸部材の接合用端面のうち一方の接合用端面の内径側に他方の接合用端面の内径より半径方向内側に突出した突出面を設け、この状態で前記溶接を行った後、当該溶接後の前記カップ部材と軸部材を水中に載置し回転させた状態で、前記他方の接合用端面を有する部材の表面側から探傷を行う超音波探傷検査工程を備えていることを特徴とする等速自在継手の外側継手部材の製造方法。 - 前記突出面をジョイントサイズ毎に同一にしたことを特徴とする請求項1に記載の等速自在継手の外側継手部材の製造方法。
- 前記突出面を前記カップ部材の接合用端面に設け、前記軸部材の表面側から斜角探触子により超音波を入射することを特徴とする請求項1又は請求項2に記載の等速自在継手の外側継手部材の製造方法。
- 前記溶接前のカップ部材と軸部材の少なくとも一方を、熱処理を施さない中間部品としたことを特徴とする請求項1〜3のいずれか一項に記載の等速自在継手の外側継手部材の製造方法。
- 前記溶接前のカップ部材と軸部材の少なくとも一方を、熱処理を施した完成部品としたことを特徴とする請求項1〜3のいずれか一項記載の等速自在継手の外側継手部材の製造方法。
- 前記溶接が電子ビーム溶接であることを特徴とする請求項1〜5のいずれか一項に記載の等速自在継手の外側継手部材の製造方法。
- 前記カップ部材と軸部材を密閉空間に設置して大気圧以下の状態で溶接することを特徴とする請求項1〜6のいずれか一項に記載の等速自在継手の外側継手部材の製造方法。
- 請求項1〜7のいずれか一項に記載の製造方法により製造された等速自在継手の外側継手部材。
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