DE10255049B4 - Method for producing a handlebar and handlebar - Google Patents

Abstract

method for producing a handlebar (1, 1a, 1b), in particular for a chassis of a motor vehicle, the two at the ends of a connecting pipe (2) attached bearing eyes (3, 3a, 3b), each consisting of a Sleeve (4, 4a) with a neck-like projection (6, 9) and one in the sleeves (4, 4a) embedded bearing element (5), characterized in that that first on the one hand a pipe string with a circular cross-section on the length plus Oversize (L) a connecting pipe (2) divided and on the other hand a strand or extruded profile (7) made with the cross-sectional configuration of the sleeves (4, 4a) and subsequently to the axial height (H) the pods (4, 4a) are separated, whereupon the bearing elements (5) in shape vulcanized rubber-metal elements in the divided sleeve tube components (8) and then both the tube raw components (8) and the connecting pipe (2) in a friction welding machine be axially displaced clamped, wherein in this clamping initially off the neck-like approaches (9) on the tube raw components (8) Pipe connections (6) Machined and ...

Description

The On the one hand, the invention relates to a process for the preparation of a Handlebar, especially for A chassis of a motor vehicle, according to the features in the preambles of the claims 1 and 2.

on the other hand The invention is directed to a handlebar according to the features in the preamble of Patent claim 5.

The DE 199 11 121 A1 discloses a handlebar for the chassis of a motor vehicle, which is composed of an aluminum alloy connecting tube and end bearing lugs, each having a sleeve made of an aluminum alloy with a neck-like approach and a bearing element embedded in the sleeve.

The Bearing elements consist of metal bushes with rubber elements, which pressed into the sleeves become. With the pressing is a comparatively high temporal and equipment required. The metal bushings must be flawless be fixed, otherwise no chassis part functionally reliable in use would.

In the known case of DE 199 11 121 A1 the bearing elements are made separately. A prefabricated bearing element contains at least one inner bush, which is enclosed by at least one rubber layer. It is also conceivable that several bushes are located with rubber blanks in such a bearing element. An outer bush made of metal or plastic then encloses the inner layers. The bearing element is calibrated after its preparation in a separate step or during the press-fitting process in the sleeve. The inner surface of the receiving opening in the sleeve must, just like the outer bushing of the bearing element have precise tolerances, so that then the bearing element can be pressed into the sleeve and to realize certain extrusion forces. A required extrusion force must be defined and maintained to ensure the secure operation of the interference fit under all forces and environmental conditions over its lifetime. The design effort is higher with aluminum handlebars than with steel components. The pressing in means an additional separate operation. In addition, it must be ensured that sufficient corrosion protection is present in the press fit under all environmental conditions.

Also is through the outer bush a bearing element a bearing eye heavier. This happens an increase unsprung masses in an axle system. This can lead to losses in ride comfort lead a motor vehicle.

The sleeves have neck-like approaches Solid material. These grab in the connecting pipe and are with this targeted by friction-stir welding (Friction Stir Welding).

The Friction stir welding is a comparatively complex welding technique on round parts. It also has the defect that at the end of the welding process at the distance the bolt-shaped Probe always a hole remains. This hole is then in use of the handlebar in question in a chassis of an increased corrosive Subjected to stress and a significant notch effect, which ultimately negatively affects the service life of the driver.

To the Add one Pipe on a blunt surface a cuboid become in the known case further welding processes called, i.a. the friction welding. However, this is not mentioned in connection with pipe connections. The described connection of a thin-walled Pipe with a large volume Quader area brings significant problems in connection technology and a significant greater notch effect on the component with him. This is the life of such a compound Limited and this only partially suitable in the chassis technology. Besides that is with a higher one Component weight connected.

Of the Invention is - starting from the prior art - the Task, a method of manufacturing a handlebar and to create a handlebar in which at reduced weight economic can be manufactured in series.

What the procedural part the solution of this When it comes to the task, there is a first variant in the characterizing one Features of claim 1.

in the This method takes particular account of the fact that the Handlebar with end bearing eyes a pronounced mass product represents. On such a mass-produced are then the manufacturing steps Optimally tuned. Accordingly, firstly on the one hand a pipe string on the length a connecting pipe plus Measurement for the joining process separated. The tubing can be made of a light alloy as well Plastics, in particular by extrusion become.

It is also conceivable that the tube strand can be made of curved and longitudinally welded blanks. This is done in particular by laser or high-frequency welding. In particular, however, the tubing string is made of an aluminum alloy. On the other hand, a strand or extrusion profile is made with the cross-sectional configuration of the sleeve having a neck-like approach. This strand or extrusion profile is then divided to the axial height of the sleeves with approach. This division can be done for example by sawing. Also, the extruded or extruded profile for the production of the sleeves may consist of any light metal alloys or plastics, but in particular but of an aluminum alloy. The advantage of aluminum alloys is that no thermal aftertreatments are necessary.

by virtue of These manufacturing steps are a total of three independent components before, a connecting tube and two sleeve tube components.

In the split sleeve raw components be targeted storage elements in the form of rubber-metal elements vulcanized. This has the advantage that the weight a bearing eye and thus a handlebar significantly reduced can be, because no additional Bushing as required when pressing in the known bearing elements is. Also, the invention has the advantage that both the sleeves as also the rubber-metal bearings can have any cross-sections. It can round or polygonal cross sections are used. Further the size of the sleeves is variable. The axes of the rubber-metal elements in the sleeves can be parallel to each other or at an angle. After vulcanization of the rubber-metal bearing in a sleeve tube component If required, this mounting unit can be calibrated. The vulcanization allows with optimal positional fixation the absorption of higher axial forces.

To the vulcanization are preferably two tube raw components and a connecting pipe in a friction welding machine clamped. Thereafter, the neck-like approaches to the Sleeve shell parts to pipe approaches machined. This can e.g. done by turning or milling.

By the fixation of connecting pipe and bearing eyes passes by friction welding in the provided with the vulcanized rubber-metal elements Sleeve shell parts a low heat input. Thus, the rubber-metal elements not damaged. However, a homogeneous fine-grained joint connection is achieved. The rubber-metal elements are no longer pressed in, as they are directly in the sleeve raw components vulcanized. This eliminates the need to edit the exact inner surfaces the sleeve raw components as well as the outer surface of the Bushings of specially made rubber-metal bearings, which are accurate for press-fitting must have. Consequently, with the omission of the jacks not only weight, but through the elimination of steps in addition to a part of the production costs saved.

By the calibrating axial cold upsetting of the joined components can be an exact defined distance tolerance of the axes of the rubber-metal elements guaranteed become.

To the calibrating cold heading of the joined components are the joints Smoothed circumferentially. This can e.g. be carried out by machining or rolling.

Of the special advantage of machining and welding including the Calibration in a single clamping results in a precisely manufactured one Component of a chassis for a motor vehicle that is always reproducible in mass production is. Alignment errors are excluded.

The Variant for producing a handlebar according to the features of the claim 2 provides that the pipe socket on a sleeve outside or inside a Friction can be produced. Furthermore, in this embodiment the vulcanization of the rubber-metal elements outside the friction welding machine. The pipe socket can be made before or after vulcanization become. Otherwise, all the described properties apply, as they do to the method of claim 1 have been cited.

A particularly advantageous embodiment one in the connecting tube and the sleeves used Aluminum alloy is seen in the features of claim 3.

Prefers reaches an aluminum alloy according to the features of claim 4 for use.

A manufactured in accordance with the steps of the claims 1 to 4 handlebars, especially for the chassis of a motor vehicle, forms part of claim 5. Also in the handlebar, it is conceivable that the connecting tube consists of any light metal alloy or plastic. Preferably, however, it is formed of an aluminum alloy. It can be extruded. But it is also conceivable the production of a board, which is tubular curved and then longitudinally welded. The sleeves can also be made of any light alloys as well Plastics exist. Preferably, however, they are made of an aluminum alloy.

The Invention is described below with reference to the drawings embodiments explained in more detail. It demonstrate:

1 in perspective, a handlebar for a chassis of a motor vehicle;

2 the handlebar of the 1 in exploded view;

3 the handlebar of the 1 in an exploded view according to another embodiment;

4 the handlebar according to 1 in an exploded view according to a third embodiment;

5 an extruded profile for producing sleeves in perspective;

6 a bearing eye of the handlebar of the 1 in the plan view;

7 a vertical longitudinal section through the bearing eye of 6 and

8th in perspective, a bearing eye of a handlebar according to another embodiment.

In the 1 is with 1 denotes a handlebar, as he can get used for example in the field of suspension on the chassis of a passenger car.

The driver 1 has a rectilinearly extending connecting tube 2 made of an aluminum alloy. End of the connecting pipe 2 are located with this by friction welding bearing eyes 3 , The bearing eyes 3 each set out from a pipe approach 6 having sleeve 4 made of an aluminum alloy and one in the sleeve 4 vulcanized rubber-metal element 5 together (see also 6 and 7 ).

The for the production of the connecting pipe 2 and the pods 4 used aluminum alloy is, in terms of weight percent, composed as follows: Si 0.69, Mn 0.33, Mg 0.26, Fe 0.20, remainder Al and melting impurities.

In the production of the handlebar 1 of the 1 On the one hand, a pipe string from the aluminum alloy described above is extruded and then to the length L of a connecting pipe 2 separated ( 2 ). On the other hand, according to the illustration of 5 an extruded profile 7 made of the aluminum alloy described above, which is the cross-sectional configuration of the sleeves 4 in the raw state. This extruded profile 7 is then then according to the dash-dotted lines in 5 to the axial height H of the sleeves 4 divided, so that sleeve raw components 8th result.

After dividing into the holes 14 the sleeve raw components 8th the rubber-metal elements 5 according to the 1 . 6 and 7 vulcanized.

After that, two with the vulcanized rubber-metal elements 5 provided sleeve raw components 8th and a connecting pipe 1 clamped in a friction welding machine, not shown. In this restraint are first of the neck-like approaches 9 the sleeve raw components 8th according to 5 the pipe connections 6 according to the particular 6 and 7 machined so that the bearing eyes 3 be formed.

Following this, the annular end faces 10 the pipe approaches 6 the sleeves 4 with the likewise annular end faces 11 of the connecting pipe 2 joined by friction welding. The outer diameter of the end faces 10 the pipe approaches 6 and the front ends 11 of the connecting pipe 2 are exactly coordinated.

After joining the bearing eyes 3 with the connecting pipe 2 are still in the same restraint the joined components 2 . 3 subjected to a calibrating axial cold compression, so that the exact distance A of the axes 12 the rubber-metal elements 5 is reached ( 1 ).

After the cold dip, the joints are also in the clamping 13 subjected to a circumferential smoothing, which can be done by machining or rolling.

The 3 shows an exploded view of a handlebar 1a with differently sized bearing eyes 3 . 3a but where are the axes 12 the bearing eyes 3 . 3a parallel to each other. The connecting pipe 2 corresponds to the one of 1 and 2 , Also, the production and joining is as in the embodiment of 1 and 2 performed.

In the 4 is an embodiment of a handlebar 1b illustrated in exploded view, in which the axes 12 equal bearing eyes 3 are rotated by 90 ° to each other. The connecting pipe 2 also corresponds to that of the 1 and 2 so that also the production and the joining as in the embodiment of 1 and 2 is made.

In the 8th is a perspective view of a bearing eye 3b illustrated, in contrast to the bearing eyes 3 . 3a of the 1 to 4 . 6 and 7 Oval or approximately rectangular is formed. The advantage is to be able to produce all desired cross-sections in the profile and then to vulcanize them. This can be used to produce various rubber grades. The sleeve raw component of this bearing eye 3b is also divided by an appropriately configured extruded profile and then with a rubber-metal element 5a provided by vulcanization. Thereafter, the further manufacturing steps as described above, so that sleeves 4a with pipe connections 6 arise. A repeated explanation is therefore unnecessary.

Instead of the manufacturing steps described above, it may also be conceivable that after the compartmenting of the tube raw components 8th from an appropriately configured in cross section extruded profile 7 These initially in a separate production process with the pipe approaches 6 provided and before or after the rubber-metal elements 5 into the sleeve raw components 8th or in the sleeves 4 vulcanized.

Thereafter, then, as described, the joining of the finished bearing eyes 3 . 3a . 3b with a connecting pipe 2 ,

1

handlebars

1a

handlebars

1b

handlebars

2

Connecting pipe v. 1 . 1a . 1b

3

Bearing eyes v. 1 . 1a . 1b

3a

bearing eye

3b

bearing eye

4

Sleeve v. 3 . 3a

4a

Sleeve v. 3b

5

Rubber-metal element v. 3 . 3a

5a

Rubber-metal element v. 3b

6

Pipe neck v. 4 . 4a

7

Strangpressprofll

8th

Sleeve shell parts

9

neck-like approaches v. 8th

10

End faces v. 6

11

End faces v. 2

12

Axles v. 5

13

joints

14

Drilling in 8th

A

distance

L

Length v. 2 plus allowance

Claims (5)

Method for producing a handlebar ( 1 . 1a . 1b ), in particular for a chassis of a motor vehicle, the two at the ends of a connecting pipe ( 2 ) mounted bearing eyes ( 3 . 3a . 3b ), each consisting of a sleeve ( 4 . 4a ) with a neck-like approach ( 6 . 9 ) and one in the sleeves ( 4 . 4a ) embedded bearing element ( 5 ), characterized in that initially on the one hand a pipe string with a circular cross-section on the length plus allowance (L) of a connecting pipe ( 2 ) and on the other hand a strand or extrusion profile ( 7 ) with the cross-sectional configuration of the sleeves ( 4 . 4a ) and then to the axial height (H) of the sleeves ( 4 . 4a ), whereupon the bearing elements ( 5 ) in the form of rubber-metal elements in the divided sleeve tube components ( 8th ) and then both the tube raw components ( 8th ) as well as the connecting tube ( 2 ) are axially displaceably clamped in a friction welding machine, wherein in this clamping initially from the neck-like approaches ( 9 ) on the sleeve raw components ( 8th ) Tube approaches ( 6 ) machined and the tube approaches ( 6 ) then via their annular end faces ( 10 ) by friction welding with the annular end faces ( 11 ) of the connecting pipe ( 2 ) and that in this clamping after the calibrating axial cold heading of the joined components ( 2 . 3 . 3a . 3b ) the joints ( 13 ) are smoothed circumferentially. Method for producing a handlebar ( 1 . 1a . 1b ), in particular for a chassis of a motor vehicle, the two at the ends of a connecting pipe ( 2 ) mounted bearing eyes ( 3 . 3a . 3b ), each consisting of a sleeve ( 4 . 4a ) with a neck-like approach ( 6 . 9 ) and one in the sleeve ( 4 . 4a ) embedded bearing element ( 5 ), characterized in that initially on the one hand a pipe string with a circular cross-section on the length (L) plus allowance of a connecting pipe ( 2 ) and on the other hand a strand or extrusion profile ( 7 ) with the cross-sectional configuration of the sleeves ( 4 . 4a ) and then to the axial height (H) of the sleeves ( 4 . 4a ), from which the nozzle-shaped approaches ( 9 ) of the divided tube raw components ( 8th ) Tube approaches ( 6 ) and the bearing elements ( 5 ) in the form of rubber-metal elements in the sleeves ( 4 . 4a ) are vulcanized, and then that both the bearing eyes thus formed ( 3 . 3a . 3b ) as well as the connecting tube ( 2 ) axially displaceably clamped in a friction welding machine and the tube approaches ( 6 ) of the sleeves ( 4 ) via their annular end faces ( 10 ) by friction welding with the annular end faces ( 11 ) of the connecting pipe ( 2 ), wherein in this clamping after a calibrating cold heading of the joined components ( 2 . 3 . 3a . 3b ) the joints ( 13 ) smoothed circumferentially become. Method according to claim 1 or 2, characterized in that in the pipe string and / or the extruded profile extrusion ( 7 ) an aluminum alloy is used, which, expressed in weight percentages, is composed as follows: Si from 0.59 to 0.81 Mn 0.28-0.38 mg 0.22 to 0.30 Fe 0.16 to 0.22 Residual Al and impurities caused by melting. Method according to one of the claims 1 to 3, characterized in that in the tubing string and / or the strand / extrusion profile ( 7 ) an aluminum alloy is used which, in terms of weight percentage, is composed as follows: Si 0.69 Mn 0.33 mg 0.26 Fe 0.20 Residual Al and impurities caused by melting. Handlebar, in particular for the chassis of a motor vehicle, manufactured according to one of the claims 1 to 4, characterized in that on the annular end faces ( 11 ) of a particular of an aluminum alloy extruded connecting tube ( 2 ) the annular end faces ( 10 ) of pipe connections ( 6 ) with vulcanized rubber-metal elements ( 5 ) provided sleeves ( 4 . 4a ) in particular an aluminum alloy as constituents of bearing eyes ( 3 . 3a . 3b ) are joined by friction welding.