CN112088259A - 弹簧的制造方法及弹簧 - Google Patents
弹簧的制造方法及弹簧 Download PDFInfo
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Abstract
本发明提供一种对负载有载荷的弹簧的应力分布进行确认的弹簧的制造方法。弹簧(1)的制造方法包括:对弹簧(1)负载载荷的工序;对负载有载荷的弹簧的应力进行测定的工序;以及释放对弹簧(1)负载的载荷的工序,弹簧(1)的应力的测定还可以包括:使用基于cosα法的X射线衍射来测定弹簧(1)的有效部的表面的应力,并对测定出的弹簧(1)的应力的大小是否满足基准进行判定的工序。
Description
技术领域
本发明涉及螺旋弹簧等弹簧的制造方法及弹簧。
背景技术
以往,在螺旋弹簧等汽车部件所使用的弹簧中,从轻量化的观点出发,要求在负载有载荷的使用时应力不会集中于弹簧的一部分的产品。弹簧的设计通过有限元法,以在设定了由形状引起的应力的分布的载荷负载时成为最佳的方式进行,但难以确认载荷负载时的实际产品的应力分布。实际上,弹簧的应力需要考虑由弹簧的形状引起的应力和通过喷丸硬化赋予的残余应力这两者来进行评价。
在现状中,由弹簧的形状引起的应力对弹簧的外形进行测量,实施通过负载有假定载荷的有限元法的分析的模拟来进行确认。另外,对于喷丸硬化后的残留应力,通过破坏检查,因此在没有负载载荷的状态下进行确认。在专利文献1中,对于喷丸硬化后的产品,提出一种通过一件一件的非破坏检查来测定残留应力的方法。
现有技术文献
专利文献
专利文献1:国际公开第2017/199959号
发明内容
发明所要解决的课题
专利文献1是仅确认喷丸硬化工序的效果的发明,与此相对,作为实际产品的弹簧存在前工序的影响,而且形状根据载荷的负载而变化,并且应力的分布也较大地变化。即,专利文献1不足以评价作为产品的弹簧。因此,需要一种在负载有载荷的状态下确认弹簧的应力分布的弹簧的制造方法及弹簧。
本实施方式是鉴于上述实际情况而提出的,其目的在于提供一种对载荷负载时的弹簧的应力分布进行确认的弹簧的制造方法及弹簧。
用于解决课题的方案
为了解决上述课题,本发明所涉及的弹簧的制造方法包括:对弹簧负载载荷的工序;在负载有载荷的状态下对弹簧的应力进行测定的工序;以及释放对弹簧负载的载荷的工序。弹簧的应力的测定也可以使用基于cosα法的X射线衍射来测定弹簧的有效部的表面的应力。在对弹簧负载载荷的工序中,也可以通过夹具来保持载荷。负载的载荷可以是从0到使用时的最大载荷。另外,假定为根据设置有弹簧的布局、目的的悬挂方式来负载载荷。
本发明的弹簧的制造方法也可以包括判定所测定的弹簧的应力的大小是否满足基准的工序。在判定工序中判定为不满足基准时,作为NG排除。
弹簧可以是螺旋弹簧、板簧、稳定器、扭杆、碟形弹簧,但并不限定于此。本发明的弹簧是通过上述的制造方法制造的。
发明效果
根据本发明,能够制造确认了载荷负载时的应力分布的弹簧,能够稳定地供给谋求轻量化而设计的弹簧。
附图说明
图1是表示本实施方式的弹簧的制造方法的一系列工序的流程图。
图2是表示本实施方式的弹簧的制造方法的载荷负载时测定应力分布的工序的流程图。
图3是表示通过夹具附加了载荷的弹簧的主视图。
图4是说明使用基于cosα法的X射线衍射的应力的测定的概观图。
图5是表示在弹簧中测定应力的方向的局部放大主视图。
图6是表示通过有限元法计算出的弹簧的形状的变化所引起的应力的分布的图。
图7是对载荷负载时和无负载时的应力测定值的差分和基于有限元法的解析值进行比较的曲线图。
图8是表示适用于冷制法的本实施方式的弹簧的制造方法的一系列工序的流程图。
具体实施方式
以下,参照附图对本实施方式的弹簧的制造方法及弹簧进行详细说明。在本实施方式中,作为弹簧,设想通过热制法制造材料的直径(d)13mm、线圈平均直径(D)112mm、自由高度(H)326mm、有效匝数(Ne)4.1、总匝数(Nt)5.5、材质SUP12的螺旋弹簧,但不限于此,也可以适用于其他的螺旋弹簧,不限于螺旋弹簧,也可以适用于其他种类的弹簧,也可以适用于冷制法。
图1是表示本实施方式的弹簧的制造方法的一系列工序的流程图。在本实施方式中,在步骤S11中对棒材进行加热,在步骤S12中将棒材成形为螺旋状的弹簧,在步骤S13中对弹簧实施淬火,在步骤S14中进行回火,在步骤S15中实施热定型。热定型在加热的状态下对弹簧负载过载荷,预先使其塑性变形,由此缓和使用时的塑性变形。在步骤S16中,对弹簧实施喷丸硬化。通过喷丸硬化,对弹簧的表面赋予预定的压缩残余应力。在步骤S17中,对弹簧实施用于涂装的前处理,在步骤S18中对弹簧实施涂装。在步骤S19中,在室温下对弹簧负载过载荷,实施预先使其塑性变形的定型,由此缓和使用时的塑性变形。
图2是表示在载荷负载时测定应力分布的工序的流程图。在步骤S21中,对弹簧负载预定的载荷。图3是表示通过夹具10负载有载荷的弹簧1的主视图。
在图3中,螺旋状的弹簧1的下侧的端匝1a被夹具10的下侧支承部10a支承,上侧的端匝1b被夹具10的上侧支承部10b支承。下侧支承部10a与上侧支承部10b的间隔能够沿着连结下侧支承部10a与上侧支承部10b的轴10c而改变,以预定的载荷作用于弹簧1的方式设定。在本实施方式中,负载7,200N的载荷并压缩。
在步骤S22中,测定弹簧的应力。在本实施方式中,使用基于cosα法的X射线衍射测定弹簧1的应力。
图4是说明使用基于cosα法的X射线衍射的应力的测定的概观图。在本实施方式的弹簧的制造方法中,使用通过cosα法测定应力的X射线衍射应力测定装置。X射线衍射应力测定装置对试样30的所需的位置照射X射线31,在X射线衍射应力测定装置的检测面21以整周检测衍射X射线32的德拜环33,由此能够通过单一的照射测定应力。
图5是表示在弹簧中测定应力的方向的局部放大主视图。在本实施方式中,在弹簧1的下侧的端匝1a以及上侧的端匝1b以外的有效部1c的外侧的表面测定扭转剪切应力。如图中的箭头35所示,在相对于弹簧1的线材延伸的方向大致45度的方向上测定应力。
表1示出X射线衍射应力测定装置的应力的测定结果。应力的单位为MPa。应力在弹簧1中,以下侧为基准,在位置P1至位置P7的七个部位各测定三次,取其平均值。另外,从位置P1到位置P7,根据图6所示的有限元法的解析结果,将应力设定为极大和极小的峰和谷。
[表1]
在此,无负载时的载荷为0N(牛顿,以下相同),负载时的载荷为7,200N,测定应力。将这些测定值的差分设为计算值,与基于有限元法的解析值进行比较。如表1所示,可以看到计算值与解析值的偏离,因此可知载荷负载状态下的应力测定是为了弹簧制品的评价而需要的。图7是对载荷负载时与无负载时的应力测定值的差分与基于有限元法的解析值进行比较的曲线图。与表1的结果同样地,在应力的测定值与基于有限元法的解析值之间存在偏离。
在图2的步骤S23中,释放弹簧1的载荷。由于结束了步骤S22中的附加了载荷的状态下的应力的测定,因此将弹簧1从夹具10上拆下。由此,弹簧1从载荷被释放。
在步骤S24中,判定在步骤S22中测定的应力是否满足基准。例如,在测定出的应力满足基准时判断为“是”(OK),在不满足基准时判断为“否”(NG)。
另外,在本实施方式中,将利用夹具10负载了载荷的弹簧1载置于架台的上表面并利用X射线衍射应力测定装置分别进行测定,但也可以取而代之,对生产线上的全部多个弹簧1测定应力。为此,也可以预先通过夹具10等对生产线上的弹簧1负载载荷,利用一台或多台X射线衍射应力测定装置测定弹簧1的预定位置。
图8是表示应用于冷制法的本实施方式的弹簧的制造方法的一系列工序的流程图。在采用冷制法的情况下,在步骤S31中将卷轴材料在常温下成型为螺旋状的弹簧,在步骤S32中对弹簧实施回火处理,在步骤S33中对弹簧实施热定型,在步骤S34中对弹簧实施喷丸硬化,在步骤S35中对弹簧实施用于涂装的前处理,在步骤S36中对弹簧实施涂装。在步骤S37中,在室温下对弹簧负载过载荷,实施预先使其塑性变形的定型,由此缓和使用时的塑性变形。在冷制法的情况下,在实施图2所示的一系列工序这一点上也是同样的。
在本实施方式的弹簧的制造方法中,使用基于cosα法的X射线衍射应力测定装置直接测定载荷负载时的弹簧的应力分布。因此,能够确认负载有载荷的弹簧的准确的应力分布,进而能够稳定地供给谋求轻量化而设计的弹簧。
产业上的利用可能性
本发明能够应用于螺旋弹簧等弹簧的制造方法和弹簧。
符号说明
1—弹簧;10—夹具。
Claims (6)
1.一种弹簧的制造方法,其特征在于,包括:
对弹簧负载载荷的工序;
在负载有所述载荷的状态下测定弹簧的应力的工序;以及
释放对所述弹簧负载的载荷的工序。
2.根据权利要求1所述的弹簧的制造方法,其特征在于,
所述弹簧的应力的测定使用基于cosα法的X射线衍射来测定所述弹簧的有效部的表面的应力。
3.根据权利要求1或2所述的弹簧的制造方法,其特征在于,
还包括判定所测定的弹簧的应力的大小是否满足基准的工序。
4.根据权利要求1至3中任一项所述的弹簧的制造方法,其特征在于,
对所述弹簧负载载荷的工序利用夹具保持载荷。
5.根据权利要求1至4中任一项所述的弹簧的制造方法,其特征在于,
所述弹簧是螺旋弹簧。
6.一种弹簧,其特征在于,
通过权利要求1至5中任一项所述的弹簧的制造方法来制造。
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