WO2015111595A1 - ステアリング用ラック、及びその製造方法 - Google Patents
ステアリング用ラック、及びその製造方法 Download PDFInfo
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- WO2015111595A1 WO2015111595A1 PCT/JP2015/051458 JP2015051458W WO2015111595A1 WO 2015111595 A1 WO2015111595 A1 WO 2015111595A1 JP 2015051458 W JP2015051458 W JP 2015051458W WO 2015111595 A1 WO2015111595 A1 WO 2015111595A1
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- WIPO (PCT)
- Prior art keywords
- rack
- teeth
- tooth
- dummy
- axial direction
- Prior art date
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D3/00—Steering gears
- B62D3/02—Steering gears mechanical
- B62D3/12—Steering gears mechanical of rack-and-pinion type
- B62D3/126—Steering gears mechanical of rack-and-pinion type characterised by the rack
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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
- B21K1/767—Toothed racks
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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
- F16H—GEARING
- F16H19/00—Gearings comprising essentially only toothed gears or friction members and not capable of conveying indefinitely-continuing rotary motion
- F16H19/02—Gearings comprising essentially only toothed gears or friction members and not capable of conveying indefinitely-continuing rotary motion for interconverting rotary or oscillating motion and reciprocating motion
- F16H19/04—Gearings comprising essentially only toothed gears or friction members and not capable of conveying indefinitely-continuing rotary motion for interconverting rotary or oscillating motion and reciprocating motion comprising a rack
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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
- F16H—GEARING
- F16H55/00—Elements with teeth or friction surfaces for conveying motion; Worms, pulleys or sheaves for gearing mechanisms
- F16H55/02—Toothed members; Worms
- F16H55/26—Racks
Definitions
- the present invention relates to a steering rack and a manufacturing method thereof.
- an automobile steering device for giving a steering angle to a steering wheel of an automobile (generally a front wheel except for a special vehicle such as a forklift) as shown in FIG.
- the movement of the steering shaft 2 is transmitted to the input shaft 6 of the steering gear 5 via the universal joints 3 and 3 and the intermediate shaft 4.
- the steering gear 5 includes a pinion that is rotationally driven by the input shaft 6 and a steering rack that meshes with the pinion.
- the steering rack When the pinion rotates together with the input shaft 6, the steering rack is displaced in the axial direction, and a pair of tie rods 7, 7 coupled to both ends thereof are pushed and pulled to give a desired steering angle to the steered wheels.
- a gear housing 9 is coupled to a lower end of the steering column 8 that passes through the steering shaft 2 inward.
- the gear housing 9 supports the electric motor 10.
- the electric motor 10 is used to apply an auxiliary force in the rotational direction to the steering shaft 2.
- FIG. 11 shows a steering device incorporating a power steering device called a dual pinion type among such electric power steering devices.
- a second input shaft 12 is disposed at a part of the steering rack 11 in the axial direction and at a portion off the pinion provided on the outer peripheral surface of the input shaft 6.
- a second pinion provided on the outer peripheral surface of one end of the second input shaft 12 is engaged with the steering rack 11.
- the electric motor 10a is supported on the side of the housing 13 provided with the second input shaft 12 inside.
- the electric motor 10 a applies a rotational force to the second input shaft 12 via the speed reducer 14. Therefore, the steering rack 11 is displaced in the axial direction by the force based on the auxiliary force and the force applied from the input shaft 6 based on the force applied to the steering wheel 1 by the driver.
- a plurality of rack teeth are provided along the axial direction on one side surface in the radial direction of the steering rack 11 except for both ends connected to a pair of tie rods 7 and 7 (see FIG. 10).
- the pitch of the pinion provided on the outer peripheral surface of the input shaft 6 and the pitch of the second pinion provided on the outer peripheral surface of the one end of the second input shaft 12 can be made different from each other.
- the angle formed by the center axis of the steering rack 11 and the angle formed by the center axis of the second input shaft 12 and the angle formed by the center axis of the steering rack 11 can be made different from each other.
- the steering rack 11a is made of a plastic material on one side in the radial direction of a rod portion 15 made of a metal material such as carbon steel or stainless steel and having a circular cross section, and a part of the rod portion 15 in the axial direction (the left portion in FIGS. 12 to 14).
- a plurality of rack teeth 16 formed by processing.
- the rod portion 15 extends over the entire length and is integrally formed of a metal material.
- a portion of the rod portion 15 that is part of the axial direction and deviates from the portion in which the plurality of rack teeth 16 are formed in the circumferential direction is referred to as a back portion 17.
- the radius of curvature R 17 (see FIG. 15) of the cross-sectional shape of the back surface portion 17 is set to the outer peripheral surface of the cylindrical portion 18 which is the other axial portion of the rod portion 15 (the right portion in FIGS. 12 to 14). Is larger than the radius of curvature r 18 (see FIG. 15) (R 17 > r 18 ).
- a method for manufacturing the steering rack 11a as described above will be described with reference to FIGS.
- a cylindrical material 19 made of a metal material such as carbon steel or stainless steel is provided in a concave groove portion 21 having an arc cross section provided on the upper surface of a receiving mold 20.
- Set (mount) is provided in which the material 19 is strongly pressed toward the concave groove portion 21 by the front end surface (lower end surface) of the long pressing punch 22 along the concave groove portion 21.
- the portion where the rack teeth 16 see FIGS.
- the intermediate material 23 is expanded.
- the intermediate material 23 has, on the outer peripheral surface, a partial cylindrical surface portion 24 to be the back surface portion 17 (see FIGS. 12, 14, and 15), and a flat surface portion 25 existing on the opposite side of the partial cylindrical surface portion 24 in the radial direction of the cross section. And a pair of curved surface portions 26, 26 having a relatively small radius of curvature that makes the partial cylindrical surface portion 24 and the flat surface portion 25 continuous.
- the intermediate material 23 is taken out from the concave groove portion 21 of the receiving mold 20 and inserted (set) into the bottom portion 29 of the holding hole 28 provided in the die 27 as shown in FIG.
- the holding hole 28 has a U-shaped cross-sectional shape.
- the curvature radius of the bottom portion 29 substantially coincides with the curvature radius of the inner surface of the concave groove portion 21 of the receiving die 20.
- both inner side surfaces 30 and 30 are mutually parallel planes.
- the upper end opening is provided with a pair of guide inclined surface portions 31 and 31 that are inclined in a direction in which the distance between the upper end openings increases toward the upper side.
- the intermediate material 23 When the intermediate material 23 is set in the holding hole 28 of the die 27, a tooth forming punch 32 is inserted into the holding hole 28 as shown in FIG.
- the intermediate material 23 is strongly pushed into the holding hole 28 by the punch 32 for use.
- the processing surface (lower surface) of the tooth forming punch 32 is provided with rack tooth processing irregularities 40 having a shape corresponding to the rack teeth 16 to be obtained.
- the outer peripheral surface of the intermediate material 23 is restrained by the inner surface of the holding hole 28 except for the flat surface portion 25 where the rack teeth 16 are to be formed. For this reason, the intermediate material 23 is strongly pushed into the holding hole 28 by the tooth forming punch 32, so that the flat surface portion 25 of the intermediate material 23 is plastically deformed following the rack tooth machining irregularities 40, as shown in FIG.
- the raw rack 33 is taken out from the holding hole 28 and mounted on the sizing uneven surface portion 36 formed on the upper surface of the sizing die 35 as shown in FIG. Put.
- the base rack 33 is turned upside down.
- the sizing uneven surface portion 36 has a shape corresponding to the shape of the rack tooth 16 to be obtained including the chamfered portion of the tooth edge (the unevenness is inverted with respect to the completed shape).
- the pressing die 37 strongly presses the portion of the base rack 33 where the rack teeth 16 are formed toward the sizing uneven surface portion 36.
- a pressing groove 38 having a radius of curvature matching the radius of curvature R 17 (see FIG. 15) of the rear surface portion 17 of the completed steering rack 11a is formed on the lower surface of the pressing die 37.
- the raw rack 33 is strongly pressed toward the concave / convex surface portion 36 for sizing in a state in which the portion to be the back portion 17 is fitted in the pressing groove 38. Therefore, with the sizing die 35 and the pressing die 37 shown in FIG. 16 (F) sufficiently close to each other, the rack teeth 16 are in the completed state (shape and shape) shown in FIG. At the same time, the dimensions and the dimensions of the back surface portion 17 are also appropriate.
- the surplus extruded as a result of the sizing performed in this way gathers at both escape flat surface portions 34 and 34. Accordingly, the two escape flat surface portions 34 and 34 hardly remain in the completed steering rack 11a. However, since the surplus does not press the sizing uneven surface portion 36 or the inner surface of the pressing groove 38 extremely strongly, not only can the processing load of the sizing be kept low, but the durability of the sizing die 35 and the pressing die 37 can be reduced. Easy to secure.
- Japanese Unexamined Patent Publication No. 10-58081 Japanese Laid-Open Patent Publication No. 2001-79639 Japanese Patent No. 3442298 Japanese Unexamined Patent Publication No. 2006-103644 Japanese Unexamined Patent Publication No. 2008-138864
- the conventional steering rack manufacturing method including the manufacturing method described in Patent Document 5 as described above may cause the following problems.
- the intermediate material 23 when the intermediate material 23 is strongly pushed into the holding hole 28 by the tooth forming punch 32, the flat surface portion 25 of the intermediate material 23 has the rack tooth machining irregularities 40 of the tooth forming punch 32. According to the above, it is plastically deformed and processed into a raw rack 33 having rack teeth 16 (see FIG. 18).
- FIG. 19 corresponding to the region A surrounded by the broken line in FIG. 18
- the teeth 39 of the tooth forming punch 32 for forming the rack teeth 16 near the intermediate portion receive an equal force f 1 from the rack teeth 16 on both sides in the axial direction at the same tooth height.
- FIG. 20 corresponding to the region B surrounded by the broken line in FIG. 18
- the rack teeth 16 at both ends in the axial direction in FIG. 18 and FIG. 20, only the rack teeth 16 at one end in the axial direction are shown).
- the present invention has been made in view of the above-described problems, and an object of the present invention is to provide a steering rack capable of extending the life of a tooth forming punch when formed by cold forging and a method for manufacturing the same. There is.
- the above object of the present invention can be achieved by the following constitution.
- the steering rack includes a rod section having a circular cross section extending in the axial direction, and a plurality of rack teeth that are formed on one side surface in a radial direction of the rod section and mesh with the pinion.
- At least one dummy tooth that is smaller than the rack tooth and does not mesh with the pinion is formed in a part of the rod portion in the axial direction and adjacent to both axial sides of the plurality of rack teeth.
- the dummy teeth connect the axial inner side surface and the axial outer side surface which are inclined in directions close to each other in the axial direction toward the radially outer side, and the axial inner side surface and the axial outer side surface.
- n dummy teeth are formed in a part of the rod portion in the axial direction and adjacent to both axial sides of the plurality of rack teeth (n is a natural number);
- the rack teeth connect the axial inner side surface and the axial outer side surface which are inclined in directions close to each other in the axial direction as they go radially outward, and the radial direction connecting the axial inner side surface and the axial outer surface.
- An outer surface, and An inclination angle of the outer side surface in the axial direction adjacent to the dummy teeth in the rack teeth located at both axial ends of the plurality of rack teeth is ⁇ 1
- the inclination angles of the axial inner side surfaces of the plurality of dummy teeth are ⁇ 2 , ⁇ 4 ,..., ⁇ 2n in order from the 1st to nth dummy teeth close to the rack teeth
- the inclination angles of the axially outer surfaces of the plurality of dummy teeth are ⁇ 3 , ⁇ 5 ,..., ⁇ 2n + 1 in order from the 1st to nth dummy teeth close to the rack teeth.
- the height of the rack teeth located at both ends in the axial direction is H 1 ,
- H 1 the heights of the plurality of dummy teeth
- H 5 the heights of the plurality of dummy teeth
- H 2n + 1 the heights of the plurality of dummy teeth
- L 1 is a half value of the tooth height H 1 of the rack teeth located at both axial ends.
- the half heights of the 1st to nth dummy teeth H 3 , H 5 ,..., H 2n + 1 are L 3 , L 5 ,.
- the force is f 2n-1 and A force generated inward in the axial direction on the axially inner side surface of the nth dummy tooth at a position L 2n radially inward from the radially outer end of the (n ⁇ 1) th dummy tooth is represented by f 2n.
- L 1 ⁇ f 1 L 2 ⁇ f 2
- L 3 ⁇ f 3 L 4 ⁇ f 4
- L 2n ⁇ 1 ⁇ f 2n ⁇ 1 L 2n ⁇ f 2n
- the steering rack according to (4).
- (6) The steering rack according to any one of (1) to (5), wherein at least one groove is formed on a radially outer surface of at least one of the dummy teeth.
- a steering rack that plastically deforms a side surface to form a plurality of rack teeth on one side surface in the radial direction
- the plurality of rack teeth mesh with a pinion that is rotationally driven by an input shaft of a steering gear that constitutes a steering apparatus for an automobile
- the tooth shaping punch has dummy tooth machining irregularities having a tooth height smaller than the rack tooth machining irregularities in portions adjacent to both axial sides of the rack tooth machining irregularities, At least one dummy tooth that is smaller than the rack tooth and does not mesh with the pinion is formed in a part of the rod portion in the axial direction and adjacent to both axial sides of the plurality of rack teeth.
- a method for manufacturing a steering rack wherein: (9) In the rack tooth forming process, the axially outer surfaces of the teeth positioned at both axial ends of the tooth forming punch are in contact with the axially inner surface of the rod portion (8) A method for producing a steering rack according to claim 1. (10) The irregularities for processing dummy teeth have at least one protrusion, At least one groove part is formed in the radial direction outer surface of at least one said dummy tooth by the said projection part, The manufacturing method of the steering rack as described in (9) characterized by the above-mentioned.
- At least one dummy tooth that is smaller than the rack tooth and does not mesh with the pinion is provided in a portion adjacent to both sides in the axial direction of the plurality of rack teeth that mesh with the pinion. Therefore, when a plurality of rack teeth are formed in the steering rack by cold forging, the rack teeth at both ends in the axial direction are formed, and the teeth of the tooth forming punch located outside the rack teeth in the axial direction A force is applied from the inner rack teeth and a force is applied from the axially outer dummy teeth. Therefore, since the balance of the moment applied to the teeth of the tooth forming punch is improved, it is possible to prevent stress from concentrating on the teeth and to extend the life of the tooth forming punch. It is.
- FIG. (A)-(F) are sectional views showing the method for manufacturing a steering rack according to the conventional structure in the order of steps, as viewed from the same direction as FIG.
- (A) And (B) is a fragmentary perspective view which shows the shape of the rack tooth before and behind sizing. It is sectional drawing for demonstrating the problem of the manufacturing method and manufacturing apparatus of the conventional rack. It is an expanded sectional view corresponding to the area
- the steering rack and the manufacturing method thereof according to the present invention are characterized in that rack teeth 16 are formed on one axial side surface of a part of the axial direction of the rod portion 15 constituting the steering rack 11a.
- rack teeth 16 are formed on one axial side surface of a part of the axial direction of the rod portion 15 constituting the steering rack 11a.
- stress is prevented from concentrating on the teeth 39 of the tooth forming punch 32, and the life of the tooth forming punch 32 is extended.
- the configuration and operation of the other parts are the same as the conventional manufacturing method and manufacturing apparatus for steering racks, including the conventional manufacturing method and manufacturing apparatus shown in FIGS. The illustrations and explanations of the parts are omitted or simplified.
- the tooth forming punch 32 according to the present embodiment is used for dummy tooth machining in the adjacent portions on both sides in the axial direction of the rack tooth machining irregularities 40 in addition to the rack tooth machining irregularities 40 described above. It has unevenness 41 (in the figure, only the unevenness 41 for dummy tooth processing on one side in the axial direction is shown).
- the tooth height 41L of the dummy tooth machining irregularities 41 is formed smaller than the tooth height 40L of the rack tooth machining irregularities 40.
- the intermediate material 23 is strongly pushed into the holding hole 28 by the tooth forming punch 32 ⁇ step corresponding to (C) ⁇ (D) in FIG. 16 described above ⁇ , the flat surface portion 25 of the intermediate material 23 is Then, it is plastically deformed following the rack tooth machining irregularities 40 and the dummy tooth machining irregularities 41 to be processed into an elementary rack 33 having the rack teeth 16 and the dummy teeth 42 as shown in FIG.
- the base rack 33 includes a rod portion 15 having a circular cross section extending in the axial direction, and a plurality of rack teeth 16 formed on one side surface in the radial direction of the rod portion 15 and meshing with the pinion.
- the dummy teeth 42 include an axial inner side surface 42a and an axial outer side surface 42b that are inclined in directions close to each other in the axial direction, and an axial inner side surface 42a and an axial outer side surface 42b. And a radially outer surface 42c to be connected.
- the radially outer surface 42c is a curved surface having an R-shaped cross section with a convex middle portion in the axial direction, and smoothly connects the axially inner side surface 42a and the axially outer surface 42b. Accordingly, the pair of connecting portions 42d of the axial inner side surface 42a and the axial outer side surface 42b and the radial outer side surface 42c are also formed in an R shape. As described above, since the dummy teeth 42 do not mesh with the pinion, there is no problem even if the radial outer surface 42c and the pair of connection portions 42d, which are tooth tips, have an R shape.
- the rack teeth 16 connect the axial inner side surface 16a and the axial outer side surface 16b, which are inclined in directions close to each other in the axial direction, toward the radially outer side, and the axial inner side surface 16a and the axial outer side surface 16b.
- a radially outer surface 16c since the rack teeth 16 mesh with the pinion, the radially outer surface 16c is formed in a flat shape, and the axial inner surface 16a and the pair of connecting portions 16d between the axially outer surface 16b and the radially outer surface 16c are It has a square shape.
- L 1 0.5 ⁇ H 1
- L 3 0.5 ⁇ H 3
- L 2 H 1 -L 3
- the radially outer end of the rack teeth 16 radially inwardly located at both axial ends at the position of L 2, the axially inner side surface 42a of the dummy teeth 42, the force f 2 occurring toward the axially inner side .
- the force f 3 occurs toward axially outward.
- a moment L 1 ⁇ f 1 is generated on the axially outer side surface 16 b of the rack tooth 16, and a moment L 2 ⁇ f 2 is generated on the axially inner side surface 42 a of the dummy tooth 42.
- a moment L 3 ⁇ f 3 is generated in 42b.
- the rack teeth 16 at both ends in the axial direction are molded, and the teeth 39 of the tooth forming punch 32 positioned on the axially outer side of the rack teeth 16 are applied to the moment L from the rack teeth 16 on the axially inner side.
- the moment L 3 ⁇ f 3 is a conventional steering rack ( 20)
- the moment L 1 ⁇ f 1 applied to the teeth 39 of the tooth forming punch 32 is smaller than L 1 ⁇ f 1 (L 3 ⁇ f 3 ⁇ L 1 ⁇ f 1 ⁇ L 3 ⁇ L 1 , F 3 ⁇ f 1 ).
- the radial outer side surface 42c and the pair of connection portions 42d of the dummy teeth 42 have an R shape, stress concentration on the roots of the teeth 39 of the tooth forming punch 32 that contacts the connection portions 42d is alleviated. Further, the life of the tooth forming punch 32 can be extended.
- FIG. 2 shows a tooth forming punch 32 (corresponding to the tooth forming punch 32 of FIG. 18) in the case where the dummy tooth machining irregularities 41 are not provided as in the prior art
- FIG. 3 shows this embodiment.
- the tooth-forming punch 32 in the form is shown, and the portions that are shown in darkness indicate that the tensile stress is large.
- FIG. 4 shows an SN diagram of the life of the tooth forming punch 32.
- the tooth forming punch 32 of the present embodiment drastically reduces the stress generated at the root of the teeth 39, so the number of repeated fractures N is greatly increased and the service life is increased. realizable.
- the dummy teeth 42 are formed one by one on the part of the rod portion 15 in the axial direction and adjacent to both sides of the rack teeth 16 in the axial direction (see FIG. 1). As shown in FIG. 5, a plurality of dummy teeth 42 may be formed on a part of the rod portion 15 in the axial direction and adjacent to both sides of the rack teeth 16 in the axial direction. Absent.
- n dummy teeth 42 are formed on one side in the axial direction (n: natural number of 2 or more). Then, the inclination angle of the axial inner side surface 42a of the plurality of dummy teeth 42 is set to ⁇ 2 , ⁇ 4 ,..., ⁇ 2n ⁇ 2 , ⁇ 2n in order from the 1st to nth dummy teeth 42 close to the rack teeth 16. And the inclination angle of the axially outer surface 42b of the plurality of dummy teeth 42 is set to ⁇ 3 , ⁇ 5 ,..., ⁇ 2n ⁇ 1 , ⁇ 2n + 1 in order from the 1st to nth dummy teeth 42 close to the rack teeth 16.
- the radially outer end of the rack teeth 16 radially inwardly located at both axial ends at the position of L 1, the axially outer side surface 16b of the rack teeth 16, the force f 1 toward the axially outward Occurs.
- the axially inner side surface 42a of the dummy teeth 42 From the radially outer end of the rack teeth 16 positioned at both axial ends radially inward at a position of L 2, the axially inner side surface 42a of the dummy teeth 42, the force f 2 occurring toward the axially inner side.
- the force f 3 occurs toward axially outward.
- a force f 2n-2 is generated toward At the position of L 2n ⁇ 1 radially inward from the radially outer end of the (n ⁇ 1) th dummy tooth 42, an axially outward force is applied to the axially outer surface 42b of the (n ⁇ 1) th dummy tooth 42.
- f 2n-1 is produced.
- a force f 2n generated inward in the axial direction is generated on the axially inner side surface 42a of the nth dummy tooth 42 at a position L 2n radially inward from the radially outer end of the (n ⁇ 1) th dummy tooth 42. Arise.
- a force f 2n + 1 is generated outward in the axial direction on the axially outer side surface 42b of the nth dummy tooth 42 at a position L 2n + 1 radially inward from the radially outer end of the nth dummy tooth 42.
- a moment L 1 ⁇ f 1 is generated on the axially outer side surface 16 b of the rack tooth 16, and a moment L 2 ⁇ f 2 is generated on the axially inner side surface 42 a of the first dummy tooth 42.
- a moment L 3 ⁇ f 3 is generated on the axially outer side surface 42 b of 42
- a moment L 4 ⁇ f 4 is generated on the axially inner side surface 42 a of the second dummy tooth 42
- the n ⁇ 1th dummy tooth 42 axially outer surface 42b is caused moment L 2n-1 ⁇ f 2n- 1, the n-th axial inner surface 42a of the dummy teeth 42 occurs moment L 2n ⁇ f 2n.
- L 1 ⁇ f 1 L 2 ⁇ f 2
- L 3 ⁇ f 3 L 4 ⁇ f 4
- L 2n-1 ⁇ f 2n-1 L 2n ⁇ f 2n
- the moments from the left and right are balanced. It is configured as follows.
- the rack teeth 16 at both ends in the axial direction are molded, and the teeth 39 of the tooth forming punch 32 positioned on the axially outer side of the rack teeth 16 are applied to the moment L from the rack teeth 16 on the axially inner side.
- 1 ⁇ f 1 is loaded, and a moment L 2 ⁇ f 2 is loaded from the dummy teeth 42 on the outer side in the axial direction.
- the tooth 39 (second tooth 39) adjacent to the outer side in the axial direction of the tooth 39 is loaded with the moment L 3 ⁇ f 3 from the first dummy tooth 42 on the inner side in the axial direction.
- a moment L 4 ⁇ f 4 is applied from the second dummy tooth 42.
- the teeth 39 at both ends of the tooth forming punch 32 are loaded with moments L 2n + 1 ⁇ f 2n + 1 from the dummy teeth 42 on the inner side in the axial direction.
- the moments L 2n + 1 ⁇ f 2n + 1 are the teeth in the first embodiment.
- the moment L 3 ⁇ f 3 applied to the teeth 39 at both ends of the molding punch 32 is small (L 2n + 1 ⁇ f 2n + 1 ⁇ L 3 ⁇ f 3 ⁇ L 2n + 1 ⁇ L 3 , f 2n + 1 ⁇ f 3 ).
- the moments L 3 ⁇ f 3 are applied to the teeth 39 of the tooth forming punch 32 located at both ends in the axial direction from the dummy teeth 42 on the inner side in the axial direction.
- the moment is not applied from the axially outer rod portion 15, but is not limited to this configuration.
- the moment is applied from the axially outer rod portion 15. Also good.
- the teeth 39 of the tooth forming punch 32 located at both ends in the axial direction abut the rod portion 15 in the axial direction.
- a moment L 0 ⁇ f 0 is generated on the axially inner side surface 15 a of the rod portion 15.
- L 0 is an arbitrary value that satisfies 0 ⁇ L 0 ⁇ H 3 .
- the moments L 3 ⁇ f 3 are applied to the teeth 39 of the tooth forming punch 32 located at both ends in the axial direction from the dummy teeth 42 on the inner side in the axial direction, and the moment L 0 ⁇ from the rod portion 15 on the outer side in the axial direction. f 0 is loaded. Therefore, since the balance of the moment is improved compared to the moment L 3 ⁇ f 3 applied to the teeth 39 at both ends of the tooth forming punch 32 in the first embodiment, stress concentrates on the teeth 39. This can be prevented, and the life of the tooth forming punch 32 can be extended. Such a configuration is particularly effective when it is difficult to increase the number of dummy teeth 42.
- the moments L 2n + 1 ⁇ f 2n + 1 are loaded on the teeth 39 of the tooth forming punch 32 located at both ends in the axial direction from the dummy teeth 42 on the axially inner side, A moment L 0 ⁇ f 0 may be applied from the rod portion 15.
- the radial outer surface 42c of the dummy tooth 42 does not necessarily have to be a curved surface having an R-shaped cross section in which the intermediate portion in the axial direction is convex, and may have a planar sectional shape as shown in FIG. Even in this case, if the pair of connecting portions 42d of the axial inner side surface 42a and the axial outer side surface 42b and the radial outer side surface 42c are formed in an R shape, the tooth forming punch that comes into contact with the connecting portion 42d is formed. It is possible to relieve stress concentration on the roots of the 32 teeth 39.
- the groove 43 is formed on the radially outer surface 42c of at least one dummy tooth 42.
- the pair of groove portions 43 has a substantially linear shape extending in the axial direction and communicating with the axial inner side surface 42a and the axial outer side surface 42b.
- the dimensions of the groove 43 are about 0.5 to 1.0 mm in width and about 0.5 to 1.0 mm in depth. Since the dummy teeth 42 do not mesh with the pinion as described above, there is no problem even if the groove portion 43 is provided on the radially outer surface 42c that is the tooth tip.
- a reference for positioning the steering rack 11a in the post-forging post-process is provided. It becomes possible to do. For example, positioning is performed by operating a probe (probe) having the same shape as the groove 43 toward the groove 43 and engaging the groove 43.
- a probe probe
- each of a pair of dummy teeth 42 (only one dummy tooth 42 on the one side in the axial direction is shown) provided at portions adjacent to both sides in the axial direction of the rack teeth 16 is shown. Since a pair of groove portions 43 are provided, and a total of four groove portions 43 are provided, positioning can be performed with higher accuracy by engaging the four probes with the four groove portions for positioning.
- the pair of dummy teeth 42 provided at the portions adjacent to the both sides in the axial direction of the rack teeth 16 have the same tooth height. Accordingly, by engaging the four probes with the four groove portions 43, detecting the positions of the respective groove portions 43, and confirming that the horizontal positions of at least the three groove portions 43 are equal, the steering rack 11a Can be leveled. Therefore, in order to enable leveling, it is necessary to form a total of three or more groove portions 43 in the plurality of dummy teeth 42 having the same tooth height.
- a projection (not shown) having a shape corresponding to the groove 43 is formed on the dummy tooth machining irregularities 41 (see FIG. 1 and the like) of the tooth forming punch 32.
- the tooth forming punch 32 has the rack tooth machining irregularities 40, the dummy tooth machining irregularities 41, and the protrusions, the rack teeth 16, the dummy teeth 42, and the groove portions 43 are provided on the steering rack 11a. It can be formed simultaneously. Therefore, since it is not necessary to process the groove 43 in a separate process, it is possible to prevent an increase in working time and cost.
- FIG. 8 shows an example in which the groove portions 43 are provided in the dummy teeth 42 in the first embodiment.
- a plurality of dummy teeth 42 are formed in adjacent portions on both sides in the axial direction of the rack teeth 16.
- the groove 43 may be provided in the dummy tooth 42.
- the steering rack 11a can be positioned.
- leveling can be performed.
- the shape of the groove 43 is not particularly limited, and may be substantially hemispherical as shown in FIG. In this case, the dimensions of the groove 43 are about 0.5 to 1.0 mm in diameter and about 0.5 to 1.0 mm in depth.
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- Power Steering Mechanism (AREA)
- Forging (AREA)
Abstract
Description
(1) 自動車用操舵装置を構成するステアリングギヤの入力軸により回転駆動されるピニオンと噛合するステアリング用ラックにおいて、
前記ステアリング用ラックは、軸方向に延びる断面円形のロッド部と、前記ロッド部の軸方向一部の径方向片側面に形成されて前記ピニオンと噛合する複数のラック歯と、を備え、
前記ロッド部の前記軸方向一部で、且つ複数の前記ラック歯の軸方向両側に隣接する部分には、前記ラック歯よりも歯丈が小さく、前記ピニオンと噛合しない少なくとも一つのダミー歯が形成される
ことを特徴とするステアリング用ラック。
(2) 前記ダミー歯は、径方向外側に向かうにしたがって、軸方向において互いに近接する方向に傾斜する軸方向内側面及び軸方向外側面と、前記軸方向内側面及び前記軸方向外側面を接続する径方向外側面と、を有し、
前記軸方向内側面及び前記軸方向外側面と、前記径方向外側面と、の一対の接続部は、R形状である
ことを特徴とする(1)に記載のステアリング用ラック。
(3) 前記ロッド部の前記軸方向一部で、且つ複数の前記ラック歯の軸方向両側に隣接する部分には、前記ダミー歯がn個ずつ形成され(nは自然数)、
前記ラック歯は、径方向外側に向かうにしたがって、軸方向において互いに近接する方向に傾斜する軸方向内側面及び軸方向外側面と、前記軸方向内側面及び前記軸方向外側面を接続する径方向外側面と、を有し、
複数の前記ラック歯のうち軸方向両端に位置する前記ラック歯における、前記ダミー歯と隣り合う前記軸方向外側面の傾斜角度をθ1とし、
複数の前記ダミー歯の前記軸方向内側面の傾斜角度を、前記ラック歯に近い1~n番目の前記ダミー歯から順にθ2、θ4、・・・、θ2nとし、
複数の前記ダミー歯の前記軸方向外側面の傾斜角度を、前記ラック歯に近い1~n番目の前記ダミー歯から順にθ3、θ5、・・・、θ2n+1とすると、
θ1<θ2≦θ3<θ4≦θ5<・・・<θ2n≦θ2n+1である
ことを特徴とする(2)に記載のステアリング用ラック。
(4) 軸方向両端に位置する前記ラック歯の歯丈をH1とし、
複数の前記ダミー歯の歯丈を、1~n番目の前記ダミー歯から順にH3、H5、・・・、H2n+1とすると、
H1>H3>H5>・・・>H2n+1である
ことを特徴とする(3)に記載のステアリング用ラック。
(5) 軸方向両端に位置する前記ラック歯の歯丈H1の半分の値をL1とし、
1~n番目の前記ダミー歯の歯丈H3、H5、・・・、H2n+1の半分の値をL3、L5、・・・、L2n+1としたとき、
L2=H1-L3、L4=H3-L5、・・・、L2n=H2n-1-L2n+1とし、
軸方向両端に位置する前記ラック歯の径方向外側端部から径方向内側にL1の位置で、前記ラック歯の前記軸方向外側面に、軸方向外側に向けて生じる力をf1とし、
軸方向両端に位置する前記ラック歯の径方向外側端部から径方向内側にL2の位置で、1番目の前記ダミー歯の前記軸方向内側面に、軸方向内側に向けて生じる力をf2とし、
n-1番目の前記ダミー歯の径方向外側端部から径方向内側にL2n-1の位置で、n-1番目の前記ダミー歯の前記軸方向外側面に、軸方向外側に向けて生じる力をf2n-1とし、
n-1番目の前記ダミー歯の径方向外側端部から径方向内側にL2nの位置で、n番目の前記ダミー歯の前記軸方向内側面に、軸方向内側に向けて生じる力をf2nとすると、
L1×f1=L2×f2、L3×f3=L4×f4、・・・、L2n-1×f2n-1=L2n×f2nである
ことを特徴とする(4)に記載のステアリング用ラック。
(6) 少なくとも一つの前記ダミー歯の径方向外側面には、少なくとも一つの溝部が形成される
ことを特徴とする(1)~(5)の何れか1項に記載のステアリング用ラック。
(7) 前記溝部は、歯丈が等しい複数の前記ダミー歯に、合計3個以上形成される
ことを特徴とする(6)に記載のステアリング用ラック。
(8) ラック状であるラック歯加工用凹凸を設けた歯成形用パンチを、軸方向に延びる金属材製のロッド部の軸方向一部の径方向片側面に押し付ける事により、前記径方向片側面を塑性変形させて前記径方向片側面に複数のラック歯を形成するステアリング用ラックの製造方法において、
前記複数のラック歯は、自動車用操舵装置を構成するステアリングギヤの入力軸により回転駆動されるピニオンと噛合し、
前記歯成形用パンチは、前記ラック歯加工用凹凸の軸方向両側に隣接する部分に、前記ラック歯加工用凹凸よりも歯丈が小さいダミー歯加工用凹凸を有し、
前記ロッド部の前記軸方向一部で、且つ複数の前記ラック歯の軸方向両側に隣接する部分には、前記ラック歯よりも歯丈が小さく、前記ピニオンと噛合しない少なくとも一つのダミー歯が形成される
ことを特徴とするステアリング用ラックの製造方法。
(9) ラック歯の成形過程において、前記歯成形用パンチの軸方向両端部に位置する歯の軸方向外側面が、前記ロッド部の軸方向内側面に当接する
ことを特徴とする(8)に記載のステアリング用ラックの製造方法。
(10) 前記ダミー歯加工用凹凸は、少なくとも一つの突起部を有し、
前記突起部により、少なくとも一つの前記ダミー歯の径方向外側面には、少なくとも一つの溝部が形成される
ことを特徴とする(9)に記載のステアリング用ラックの製造方法。
図1に示すように、本実施形態の歯成形用パンチ32は、上述のラック歯加工用凹凸40に加えて、当該ラック歯加工用凹凸40の軸方向両側に隣接する部分にダミー歯加工用凹凸41を有している(図中、軸方向一方側のダミー歯加工用凹凸41のみが示されている。)。ダミー歯加工用凹凸41の歯丈41Lは、ラック歯加工用凹凸40の歯丈40Lよりも小さく形成されている。
上述の実施形態では、ロッド部15の軸方向一部で且つ複数のラック歯16の軸方向両側に隣接する部分に、一つずつダミー歯42が形成される構成であったが(図1参照)、図5に示すように、ロッド部15の軸方向一部で且つ複数のラック歯16の軸方向両側に隣接する部分に、複数個ずつダミー歯42が形成される構成であっても構わない。
2 ステアリングシャフト
3 自在継手
4 中間シャフト
5 ステアリングギヤ
6 入力軸
7 タイロッド
8 ステアリングコラム
9 ギヤハウジング
10、10a 電動モータ
11、11a ステアリング用ラック
12 第二の入力軸
13 ハウジング
14 減速機
15 ロッド部
15a 軸方向内側面
16 ラック歯
16a 軸方向内側面
16b 軸方向外側面
16c 径方向外側面
16d 接続部
17 背面部分
18 円筒部
19 素材
20 受型
21 凹溝部
22 押圧パンチ
23 中間素材
24 部分円筒面部
25 平坦面部
26 曲面部
27 ダイス
28 保持孔
29 底部
30 内側面
31 ガイド傾斜面部
32 歯成形用パンチ
33 素ラック
34 逃げ平坦面部
35 サイジング用ダイス
36 サイジング用凹凸面部
37 押型
38 押し凹溝
39 歯
40 ラック歯加工用凹凸
40L 歯丈
41 ダミー歯加工用凹凸
41L 歯丈
42 ダミー歯
42L 歯丈
42a 軸方向内側面
42b 軸方向外側面
42c 径方向外側面
42d 接続部
43 溝部
A、B 領域
C 亀裂
R17、r18 曲率半径
Claims (10)
- 自動車用操舵装置を構成するステアリングギヤの入力軸により回転駆動されるピニオンと噛合するステアリング用ラックにおいて、
前記ステアリング用ラックは、軸方向に延びる断面円形のロッド部と、前記ロッド部の軸方向一部の径方向片側面に形成されて前記ピニオンと噛合する複数のラック歯と、を備え、
前記ロッド部の前記軸方向一部で、且つ複数の前記ラック歯の軸方向両側に隣接する部分には、前記ラック歯よりも歯丈が小さく、前記ピニオンと噛合しない少なくとも一つのダミー歯が形成される
ことを特徴とするステアリング用ラック。 - 前記ダミー歯は、径方向外側に向かうにしたがって、軸方向において互いに近接する方向に傾斜する軸方向内側面及び軸方向外側面と、前記軸方向内側面及び前記軸方向外側面を接続する径方向外側面と、を有し、
前記軸方向内側面及び前記軸方向外側面と、前記径方向外側面と、の一対の接続部は、R形状である
ことを特徴とする請求項1に記載のステアリング用ラック。 - 前記ロッド部の前記軸方向一部で、且つ複数の前記ラック歯の軸方向両側に隣接する部分には、前記ダミー歯がn個ずつ形成され(nは自然数)、
前記ラック歯は、径方向外側に向かうにしたがって、軸方向において互いに近接する方向に傾斜する軸方向内側面及び軸方向外側面と、前記軸方向内側面及び前記軸方向外側面を接続する径方向外側面と、を有し、
複数の前記ラック歯のうち軸方向両端に位置する前記ラック歯における、前記ダミー歯と隣り合う前記軸方向外側面の傾斜角度をθ1とし、
複数の前記ダミー歯の前記軸方向内側面の傾斜角度を、前記ラック歯に近い1~n番目の前記ダミー歯から順にθ2、θ4、・・・、θ2nとし、
複数の前記ダミー歯の前記軸方向外側面の傾斜角度を、前記ラック歯に近い1~n番目の前記ダミー歯から順にθ3、θ5、・・・、θ2n+1とすると、
θ1<θ2≦θ3<θ4≦θ5<・・・<θ2n≦θ2n+1である
ことを特徴とする請求項2に記載のステアリング用ラック。 - 軸方向両端に位置する前記ラック歯の歯丈をH1とし、
複数の前記ダミー歯の歯丈を、1~n番目の前記ダミー歯から順にH3、H5、・・・、H2n+1とすると、
H1>H3>H5>・・・>H2n+1である
ことを特徴とする請求項3に記載のステアリング用ラック。 - 軸方向両端に位置する前記ラック歯の歯丈H1の半分の値をL1とし、
1~n番目の前記ダミー歯の歯丈H3、H5、・・・、H2n+1の半分の値をL3、L5、・・・、L2n+1としたとき、
L2=H1-L3、L4=H3-L5、・・・、L2n=H2n-1-L2n+1とし、
軸方向両端に位置する前記ラック歯の径方向外側端部から径方向内側にL1の位置で、前記ラック歯の前記軸方向外側面に、軸方向外側に向けて生じる力をf1とし、
軸方向両端に位置する前記ラック歯の径方向外側端部から径方向内側にL2の位置で、1番目の前記ダミー歯の前記軸方向内側面に、軸方向内側に向けて生じる力をf2とし、
n-1番目の前記ダミー歯の径方向外側端部から径方向内側にL2n-1の位置で、n-1番目の前記ダミー歯の前記軸方向外側面に、軸方向外側に向けて生じる力をf2n-1とし、
n-1番目の前記ダミー歯の径方向外側端部から径方向内側にL2nの位置で、n番目の前記ダミー歯の前記軸方向内側面に、軸方向内側に向けて生じる力をf2nとすると、
L1×f1=L2×f2、L3×f3=L4×f4、・・・、L2n-1×f2n-1=L2n×f2nである
ことを特徴とする請求項4に記載のステアリング用ラック。 - 少なくとも一つの前記ダミー歯の径方向外側面には、少なくとも一つの溝部が形成される
ことを特徴とする請求項1~5の何れか1項に記載のステアリング用ラック。 - 前記溝部は、歯丈が等しい複数の前記ダミー歯に、合計3個以上形成される
ことを特徴とする請求項6に記載のステアリング用ラック。 - ラック状であるラック歯加工用凹凸を設けた歯成形用パンチを、軸方向に延びる金属材製のロッド部の軸方向一部の径方向片側面に押し付ける事により、前記径方向片側面を塑性変形させて前記径方向片側面に複数のラック歯を形成するステアリング用ラックの製造方法において、
前記複数のラック歯は、自動車用操舵装置を構成するステアリングギヤの入力軸により回転駆動されるピニオンと噛合し、
前記歯成形用パンチは、前記ラック歯加工用凹凸の軸方向両側に隣接する部分に、前記ラック歯加工用凹凸よりも歯丈が小さいダミー歯加工用凹凸を有し、
前記ロッド部の前記軸方向一部で、且つ複数の前記ラック歯の軸方向両側に隣接する部分には、前記ラック歯よりも歯丈が小さく、前記ピニオンと噛合しない少なくとも一つのダミー歯が形成される
ことを特徴とするステアリング用ラックの製造方法。 - ラック歯の成形過程において、前記歯成形用パンチの軸方向両端部に位置する歯の軸方向外側面が、前記ロッド部の軸方向内側面に当接する
ことを特徴とする請求項8に記載のステアリング用ラックの製造方法。 - 前記ダミー歯加工用凹凸は、少なくとも一つの突起部を有し、
前記突起部により、少なくとも一つの前記ダミー歯の径方向外側面には、少なくとも一つの溝部が形成される
ことを特徴とする請求項9に記載のステアリング用ラックの製造方法。
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- 2015-01-21 WO PCT/JP2015/051458 patent/WO2015111595A1/ja active Application Filing
- 2015-01-21 EP EP15740585.3A patent/EP3098138B1/en active Active
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Also Published As
Publication number | Publication date |
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JPWO2015111595A1 (ja) | 2017-03-23 |
JP6202109B2 (ja) | 2017-09-27 |
US10392046B2 (en) | 2019-08-27 |
EP3098138B1 (en) | 2019-03-13 |
CN105939919A (zh) | 2016-09-14 |
US20170008551A1 (en) | 2017-01-12 |
EP3098138A4 (en) | 2017-09-20 |
US11021184B2 (en) | 2021-06-01 |
US20190047609A1 (en) | 2019-02-14 |
EP3098138A1 (en) | 2016-11-30 |
CN105939919B (zh) | 2018-03-13 |
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