CN101642789B - 在板上形成凸起的方法及使用中将承受周期性疲劳载荷的具有凸起的板 - Google Patents

在板上形成凸起的方法及使用中将承受周期性疲劳载荷的具有凸起的板 Download PDF

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CN101642789B
CN101642789B CN2009101366480A CN200910136648A CN101642789B CN 101642789 B CN101642789 B CN 101642789B CN 2009101366480 A CN2009101366480 A CN 2009101366480A CN 200910136648 A CN200910136648 A CN 200910136648A CN 101642789 B CN101642789 B CN 101642789B
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菲斯克理查德·威廉
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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
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C33/00—Parts of bearings; Special methods for making bearings or parts thereof
    • F16C33/30—Parts of ball or roller bearings
    • F16C33/58—Raceways; Race rings
    • F16C33/60—Raceways; Race rings divided or split, e.g. comprising two juxtaposed rings
    • F16C33/605—Raceways; Race rings divided or split, e.g. comprising two juxtaposed rings with a separate retaining member, e.g. flange, shoulder, guide ring, secured to a race ring, adjacent to the race surface, so as to abut the end of the rolling elements, e.g. rollers, or the cage
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D19/00—Flanging or other edge treatment, e.g. of tubes
    • B21D19/08—Flanging or other edge treatment, e.g. of tubes by single or successive action of pressing tools, e.g. vice jaws
    • B21D19/088—Flanging or other edge treatment, e.g. of tubes by single or successive action of pressing tools, e.g. vice jaws for flanging holes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D28/00—Shaping by press-cutting; Perforating
    • B21D28/24—Perforating, i.e. punching holes
    • B21D28/34—Perforating tools; Die holders
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/24—Making other particular articles nuts or like thread-engaging members
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/06—Surface hardening
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D7/00—Modifying the physical properties of iron or steel by deformation
    • C21D7/02—Modifying the physical properties of iron or steel by deformation by cold working
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    • F16C33/00—Parts of bearings; Special methods for making bearings or parts thereof
    • F16C33/30—Parts of ball or roller bearings
    • F16C33/58—Raceways; Race rings
    • F16C33/583—Details of specific parts of races
    • F16C33/586—Details of specific parts of races outside the space between the races, e.g. end faces or bore of inner ring
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    • F16C33/00—Parts of bearings; Special methods for making bearings or parts thereof
    • F16C33/30—Parts of ball or roller bearings
    • F16C33/58—Raceways; Race rings
    • F16C33/64—Special methods of manufacture
    • 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
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C35/00—Rigid support of bearing units; Housings, e.g. caps, covers
    • F16C35/04—Rigid support of bearing units; Housings, e.g. caps, covers in the case of ball or roller bearings
    • F16C35/06—Mounting or dismounting of ball or roller bearings; Fixing them onto shaft or in housing
    • 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
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C35/00—Rigid support of bearing units; Housings, e.g. caps, covers
    • F16C35/04—Rigid support of bearing units; Housings, e.g. caps, covers in the case of ball or roller bearings
    • F16C35/06—Mounting or dismounting of ball or roller bearings; Fixing them onto shaft or in housing
    • F16C35/067—Fixing them in a housing
    • 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
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C2226/00—Joining parts; Fastening; Assembling or mounting parts
    • F16C2226/50—Positive connections
    • F16C2226/52—Positive connections with plastic deformation, e.g. caulking or staking
    • 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
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C2226/00—Joining parts; Fastening; Assembling or mounting parts
    • F16C2226/50—Positive connections
    • F16C2226/60—Positive connections with threaded parts, e.g. bolt and nut connections
    • 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
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C2361/00—Apparatus or articles in engineering in general
    • F16C2361/61—Toothed gear systems, e.g. support of pinion shafts
    • 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
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C35/00—Rigid support of bearing units; Housings, e.g. caps, covers
    • F16C35/04—Rigid support of bearing units; Housings, e.g. caps, covers in the case of ball or roller bearings
    • F16C35/042—Housings for rolling element bearings for rotary movement
    • F16C35/045—Housings for rolling element bearings for rotary movement with a radial flange to mount the housing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49636—Process for making bearing or component thereof
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49636—Process for making bearing or component thereof
    • Y10T29/49643—Rotary bearing
    • Y10T29/49679—Anti-friction bearing or component thereof
    • Y10T29/49689—Race making
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49636—Process for making bearing or component thereof
    • Y10T29/49696—Mounting
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49826—Assembling or joining
    • Y10T29/49947—Assembling or joining by applying separate fastener
    • Y10T29/49963—Threaded fastener

Abstract

公开了一种在板上形成凸起的方法，该板在使用中将承受周期性疲劳载荷，该方法包括：选择具有超过0.35的高应变硬化系数的板材料，以及贴靠模具挤压成形凸起，使原始板与凸起的壁之间的区域的曲率半径满足下列公式：半径＝板厚度×A其中，“A”值在0.3和0.7之间，这样，凸起的弯曲部在载荷下加工硬化，以产生具有高局部拉伸强度的区域。

Description

在板上形成凸起的方法及使用中将承受周期性疲劳载荷的具有凸起的板
本申请是申请日为2004年09月03日、申请号为200480032224.5、发明名称为“轴承组件”的申请的分案申请。 
技术领域
本发明涉及一种轴承组件的结构和制造该轴承组件的方法，该轴承组件特别适用于在没有通向轴承座的紧固工具通道的极其紧凑的机器装置中轴承承受轴向载荷的场合，和希望机器人进行机器装配的场合。
背景技术
本发明起因于解决在小型车辆齿轮箱中装配轴承的问题，其中，轴承与许多其它元件诸如齿轮一起支撑齿轮箱的齿轮轴的轴颈。这将在下文进行说明，但除非另有说明，本发明可以用于许多其它类似的结构中。在这种齿轮箱中，齿轮轴以其轴颈支撑在轴承上，并且该轴承被容纳在齿轮箱壳体中形成的轴承座中。外圈的配合是典型的工程干涉配合或者类似的定位方法，这样，该外圈不会自由地占据不同的角度方向。在运转过程中，轴承受轴向载荷，该轴向载荷迫使轴承沿各轴向离开其轴承座。这种轴向地离开壳体的力由壳体上形成的肩部抵抗。然而，必须在轴承外座圈(outer race)和壳体之间设置保持机构(retaining means)，以避免沿相反方向的轴向位移。传统机构的一个例子可以是开口弹簧环圈(circlip)，该开口弹簧环圈被容纳在轴承座壁上形成的槽内。可是，安装这种保持机构需要工具进入壳体内部的通道，用机器人操作是困难的。此外，使用开口弹簧环圈和类似机构需要轴承外座圈和开口弹簧环圈之间是松配合，这就使轴承有不希 望的轴向运动，并在轴向上占据空间。再者，没有良好的工具通道，开口弹簧环圈和类似机构不容易拆卸。如果这种通道的需求可以排除，就可以实施机器人装配，齿轮箱的体积可以减小，其巨大的利益对于本领域的技术人员是显而易见的。
在现有技术中，还已知EP1265339，其公开了马达中的一种轴承组件。首先，将保持板临时安装在轴上。再用轴承支撑轴的轴颈。然后，以将轴承外座圈插入轴承座的状态将装配好的保持板和轴承插入马达壳体中。这里存在一个问题，因为在运转之前，必须将保持板从轴上拆卸。此外，保持板不能设置成与轴承的内端平齐，所以，轴承和轴承座组件的轴向长度没有被最小化。
发明内容
因此，为了使这些问题得以缓解，本发明提供了一种轴承组件，其包括：
轴承，该轴承具有外座圈，其容纳在壳体中形成的轴承座内、和内座圈，其支撑轴的轴颈；以及保持板，在组装到轴承座内或者安装在轴上之前，该保持板安装在外座圈上，并设置有紧固机构，该紧固机构与设置在壳体的壁内或壁上、面对保持板的紧固机构协同工作。
对于某些应用，可将保持板设置成不可旋转地紧固，例如使用压配合。然而，在本发明的优选实施例中，保持板被紧固，使其可相对于外座圈旋转，从而，在外座圈被不可旋转地保持在轴承座内后，保证紧固机构方便地对准。
也根据本发明，提供了一种制造轴承组件的方法，该方法包括下列步骤：
将保持板安装在轴承的外座圈上，从而当轴承座落在轴承座内时，轴承被保持板轴向保持，保持板由在其中形成有轴承座的 壳体与保持板之间起作用的紧固机构固定。
根据本发明的另一方面，提供了一种在板上形成凸起的方法，该板在使用时将承受周期性疲劳载荷，该方法包括：
选择具有超过0.35的高应变硬化系数的板材料；以及
贴靠模具挤压成形所述凸起，使原始板与所述凸起的壁之间区域的曲率半径满足下列公式，
半径＝板厚度×A
其中，“A”值在0.3和0.7之间，这样，凸起的弯曲部在载荷下加工硬化，以产生具有高局部拉伸强度的区域。
本发明的轴承组件缓解了上述问题，这从下文对轴承组件及形成这种轴承组件的方法的一个实施例所做的不具限制性的详细说明是显而易见的。
附图说明
图1为齿轮箱体的剖视图，其示出了在安装到在壳体内形成的轴承座的过程中的轴承组件；
图2为通过模具冲头剖切的放大剖视图，其示出了在轴承组件的保持板上的咬合部的形成；
图3为在保持板安装在轴承组件上时，从轴承的肩部剖切的放大剖视图；
图4为示出了咬合部与保持板上的槽的接合状态的放大剖视图；
图5为保持板单独的剖视图；
图6为保持板的俯视图；
图7A和7B示出了在保持板上的凸起的形成。
具体实施方式
参看附图，图1示出了轴承组件，该轴承组件包括轴承1，该轴承1具有外座圈，其容纳于在车辆齿轮箱的壳体3中形成的轴承座2中。轴承1的内座圈支撑轴4的轴颈。轴承1被容纳至轴承座2中，使轴承1贴靠在轴承座内形成的肩部5，以避免轴承沿轴向(相对于轴)移到壳体3之外。为避免轴承1沿相反的轴向发生位移，安装保持板6，使其相对于轴承1的外座圈转动。当轴承1座落于轴承座内时，由在保持板6上形成的带螺纹的凸起7提供的紧固机构，均对准穿透壳体3上形成的通孔8，这样，可以通过这些通孔拧动螺钉9，以与凸起7接合并保持保持板6。因此，可以安装轴承组件，使安装在轴上的零件10与保持板极其靠近，以避免在保持板与零件之间进行工具的操作，而壳体包围轴承轴、零件和保持板，达到紧固工具不能在保持板上进行操作的程度。这又允许在轴承组件和轴装配之前，更多的零件例如齿轮10以极其靠近轴承1的方式安装在轴上。
保持板6通过首先冲出凸起7，由金属带制成。再冲出中央孔11。然后，沿绕保持板6的圆形内边缘彼此隔开的圆弧形成多个咬合部12。本实施例中形成三个唇缘，然而，根据具体要求可以形成二至五个唇缘。
图2示出使用专门设计的冲压工具来形成咬合部。孔11定位于环绕圆形引导部14的冲模板13上。然后，在驱动精压冲头16在距孔的边缘一小段距离处压入保持板表面一部分之前，环形压板(platen ring)15压靠保持板的曝露表面。精压冲头具有楔形刀片(wedge shaped blade)17，此楔形刀片与保持板表面接合，使保持板的边缘塑性变形，从而在保持板的边缘形成唇缘，该唇缘从保持板的表面向上，即沿轴向方向延伸，并沿远离孔的边缘留下槽18。精压冲头还可以在圆弧的每一端形成凹口(notch)19，以控制每一端的变形。由精压冲头引起变形的每段圆弧，以从12 度至36度之间的圆弧延伸，所以变形的边缘部分总共占10％至30％。
在轴承1的外座圈的边缘形成肩部20。在肩部20形成三角形槽21，该槽邻近构成肩部的轴表面22。在本实施例中，槽的深度大约为0.3-0.4mm，并且咬合部12具有类似的高度。保持板上的孔的尺寸制成大于肩部20的直径。
为了使保持板6紧固在轴承1上，在咬合部12与轴表面22接合的状态下，保持板在轴承上定位。值得注意的是，孔11与肩部20的配合，是如图3和图4所示被放大的间隙所表明的松配合。然后，沿图3中箭头所示方向施加装配力，使咬合部12塑性变形，使其如图4所示接合于槽21中。
保持板6上还设有形状为“U”形的支架23的保持元件，形状为“U”形的支架23从保持板的外周突出。“U”形板的叉部与变速支撑杆(gear change support rod)(未示出)接合。
不希望保持板的尺度大于任何所需尺度，以使保持板占据的空间最小化。关键的是使轴承保持在其最小移动下，所以需要紧固机构向保持板提供贴靠轴承的轴表面的夹紧作用。进一步的情况是，保持板在运转过程中承受体现金属疲劳问题的周期性载荷。传统地在保持板上冲压成形凸起，由于板的加工硬化，加剧了金属疲劳问题，所以冲压成形凸起是不可取的。然而，与可供替代的形成紧固机构的传统方法相比，冲压成形具有显著的经济性。用冲压成形凸起的另外一个问题是要保证凸起端面精确平整。
为了使凸起能冲压成形，保持板可方便地由具有高应变硬化系数的材料形成。优选的例子是奥氏体不锈钢牌号304和普通碳钢牌号1020-1040。另外一种方法是选择一种高可成形性材料，并在凸起成形之后对其进一步处理，例如进行表面硬化处理或者氮化处理，以改善其抗疲劳性。
图7A和7B示出了所设计的用于凸起成形的工具。该工具包括具有弯曲边缘(arcuate rim)25的模具24。圆弧的半径必须仔细形成，以避免在保持板6出现缩颈现象(necking)。圆弧半径优选满足下列公式：
半径＝板厚度×A
其中，“A”值在0.3和0.7之间选取。
冲头26是特别成形的，以确保在与模具协同工作的情况下，凸起7的端面“F”平直并成直角。
尽管所述实施例使用螺钉紧固板，在本发明范围内，可以使用其它紧固机构，例如可以使用铆钉。

Claims (4)

1.一种在板上形成凸起的方法，该板在使用中将承受周期性疲劳载荷，该方法包括：
选择具有超过0.35的高应变硬化系数的板材料，以及
贴靠模具挤压成形所述凸起，使原始板与所述凸起的壁之间的区域的曲率半径满足下列公式：
半径＝板厚度×A
其中，“A”值在0.3和0.7之间，这样，所述凸起的弯曲部在载荷下加工硬化，以产生具有高局部拉伸强度的区域。
2.根据权利要求1所述的在板上形成凸起的方法，其中，所述板的材料是奥氏体不锈钢牌号304。
3.一种在使用中将承受周期性疲劳载荷的具有凸起的板，该板选择具有超过0.35的高应变硬化系数的板材料，原始板与所述凸起的壁之间的区域的曲率半径满足下列公式：
半径＝板厚度×A
其中，“A”值在0.3和0.7之间。
4.根据权利要求3所述的在使用中将承受周期性疲劳载荷的具有凸起的板，其中，所述板的材料是奥氏体不锈钢牌号304。
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