JP2004169063A - Rotator having excellent fatigue strength and long service life and its production method - Google Patents

Rotator having excellent fatigue strength and long service life and its production method Download PDF

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Publication number
JP2004169063A
JP2004169063A JP2002333194A JP2002333194A JP2004169063A JP 2004169063 A JP2004169063 A JP 2004169063A JP 2002333194 A JP2002333194 A JP 2002333194A JP 2002333194 A JP2002333194 A JP 2002333194A JP 2004169063 A JP2004169063 A JP 2004169063A
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rotating body
cold
fatigue strength
metal plate
tensile
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JP2002333194A
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JP4261879B2 (en
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Noriyoshi Tominaga
知徳 冨永
Masataka Takagi
優任 高木
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Nippon Steel Corp
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Nippon Steel Corp
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Priority to JP2002333194A priority Critical patent/JP4261879B2/en
Priority to PCT/JP2003/014594 priority patent/WO2004046393A1/en
Priority to KR1020057008790A priority patent/KR100676934B1/en
Priority to CNB2003801035046A priority patent/CN100529113C/en
Priority to AU2003280831A priority patent/AU2003280831A1/en
Publication of JP2004169063A publication Critical patent/JP2004169063A/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B3/00—Disc wheels, i.e. wheels with load-supporting disc body
    • B60B3/002—Disc wheels, i.e. wheels with load-supporting disc body characterised by the shape of the disc
    • 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
    • B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
    • 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
    • B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
    • B23K31/02—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 soldering or welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B3/00—Disc wheels, i.e. wheels with load-supporting disc body
    • B60B3/04—Disc wheels, i.e. wheels with load-supporting disc body with a single disc body not integral with rim, i.e. disc body and rim being manufactured independently and then permanently attached to each other in a second step, e.g. by welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B3/00—Disc wheels, i.e. wheels with load-supporting disc body
    • B60B3/04—Disc wheels, i.e. wheels with load-supporting disc body with a single disc body not integral with rim, i.e. disc body and rim being manufactured independently and then permanently attached to each other in a second step, e.g. by welding
    • B60B3/041—Disc wheels, i.e. wheels with load-supporting disc body with a single disc body not integral with rim, i.e. disc body and rim being manufactured independently and then permanently attached to each other in a second step, e.g. by welding characterised by the attachment of rim to wheel disc
    • B60B3/044—Disc wheels, i.e. wheels with load-supporting disc body with a single disc body not integral with rim, i.e. disc body and rim being manufactured independently and then permanently attached to each other in a second step, e.g. by welding characterised by the attachment of rim to wheel disc characterised by cross-sectional details of the attachment, e.g. the profile
    • 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
    • C21D7/04—Modifying the physical properties of iron or steel by deformation by cold working of the surface

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Butt Welding And Welding Of Specific Article (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)
  • Heat Treatment Of Articles (AREA)

Abstract

<P>PROBLEM TO BE SOLVED: To provide a rotator having excellent fatigue strength and long service life which uses metallic sheets having a lap fillet-welded joint, a cold-bend working part, a punch-out hole, etc., receiving repeated loads with the rotation, such as load-wheel for car, pulley, gear, driving wheel in caterpillar. <P>SOLUTION: In the rotator having the lap fillet-welded joint welding the edge parts by piling up two metallic sheets, cold-bend working part, punch-out hole, etc., a pressed trace is formed or the surface is smoothened by applying an ultrasonic shock treatment to anyone, and a tension residual stress is relaxed to obtain the rotator having excellent fatigue strength and long service life, and its producing method. <P>COPYRIGHT: (C)2004,JPO

Description

【０００１】
【発明の属する技術分野】
本発明は、金属板を用いた疲労強度に優れた長寿命回転体およびその製造方法に関する。
例えば、自動車用ロードホイール、プーリー、ギア、キャタピラーの動輪など、回転により繰り返し荷重を受ける重ね隅肉溶接継手、冷間曲げ加工部、打ち抜き穴等を有する疲労強度に優れた長寿命回転体およびその製造方法に関する。
【０００２】
【従来技術】
回転による繰り返し荷重を受ける、自動車用ロードホイール、プーリー、ギア、キャタピラーの動輪などの回転体は、重ね隅肉溶接継手、冷間曲げ加工部、打ち抜き穴等の金属疲労上の弱点を持つ。
これら、溶接、冷間曲げ加工、打ち抜きなどの加工後の後処理による溶接ビード形状や疲労強度の向上手法としては、従来、▲１▼グラインディング、▲２▼ＴＩＧドレッシング、▲３▼ショットピーニング、▲４▼ハンマーピーニングが用いられてきた。これらの手法は、応力集中部となる溶接止端部の形状を整形して応力集中を緩和する、もしくは残留応力を変化させて疲労強度を向上するというものである。しかし、これらの手法でも、以下のような問題点があった。
【０００３】
ここで、グラインディング、ＴＩＧドレッシングは、応力集中部の形状を応力集中の少ない形状に整形することによって疲労強度を向上させるという手法である。しかし、これらは、重ね隅肉溶接継手や、打ち抜き穴の疲労強度の向上には効果があるが、冷間曲げ加工部については効果を持たないうえ、作業効率が著しく低く、大量生産品への使用には向いていなかった。さらに、グラインディングでは、歯を当てる方向が応力作用方向に直角の場合、かえって疲労き裂が進展しやすい処理痕ができてしまう場合があるなど、処理に技能が要求されるという面もある。
ところで、溶接部には一般に溶接入熱による局部的な熱膨張とその後の冷却による熱収縮によって残留応力が導入される。また、冷間加工部にも塑性変形に伴う大きな残留応力が存在する。このような残留応力が疲労強度を低下させる一つの大きな要因となっている。
そこで、疲労強度を向上させる別の手段として、圧縮残留応力を発生させるか、あるいは引張残留応力を低減して疲労強度を高める、ショットピーニングやハンマーピーニングなどの方法が知られている。なお、ショットピーニング処理は、疲労き裂発生の起点となる部位に、１ｍｍ弱の鋼球を多数打ち付け圧縮残留応力を付与する手法である。また、ハンマーピーニングは圧搾空気などを利用してピンを作動させ、処理部を叩くという手法である。
【０００４】
しかし、ショットピーニングは巨大な機械が必要であるうえ、使用時にチャンバーが必要なのでやはり大量生産品への使用については効率が悪く、種々のユーティリティが必要となる。また、必要なところだけを処理するという箇所選択性が著しく劣るために、意匠性が求められる場合には使えなかった。
また、ハンマーピーニングは反動が大きく、また、あまりに大きな塑性変形を与えるために、薄い板に対しては使いにくいという欠点もあった。
さらに、ハンマーピーニングでは、数Ｈｚの低周波の機械加工を継手部に施すため加工表面の凹凸が激しく、その凹部が応力集中部となって、疲労き裂の起点となるために処理結果が安定せず、ときには継手全体の疲労強度が却って低下する場合があるという問題点があった。
【０００５】
さらに、溶接金属の加熱再溶融により溶接止端部形状の改善あるいは引張残留応力の軽減が可能であることも知られている。しかし、この手法も著しく効率が低いという問題があるうえ、効果もそれほど大きくない。
【０００６】
以上のように、従来の疲労強度の向上技術を、自動車用ホイールをはじめとする回転体について採用することは困難であり、たとえ採用できても疲労強度向上代が低いレベルに留まっていた。そのため、材料の高強度化により対応してきたが、打ち抜き端面の疲労に対する感受性が、鋼材の強度が６００Ｎ／ｍｍ２級以上になると、急激に高くなってしまうため、疲労向上効果は頭打ちとなってしまうという問題点があった。
なお、溶接継手部に超音波振動を与えることによって、疲労強度を向上させる方法に関する従来技術としては、例えば、米国特許第６，１７１，４１５号明細書に、溶接アークによって熱せられた溶接シーム部に沿って超音波振動を付与する方法が開示されている。
しかし、この従来技術は、溶接直後の高温の材料に超音波振動を与えることを前提としているうえ、本発明が提案しているような超音波振動子で打撃する具体的な対象物および処理範囲の開示がない。
【０００７】
【特許文献１】
米国特許第６，１７１，４１５号明細書
【０００８】
【発明が解決しようとする課題】
本発明は、前述のような従来技術の問題点を解決し、自動車用ホイール、プーリー、ギア、キャタピラーの動輪など、回転により繰り返し荷重を受ける重ね隅肉溶接継手、冷間曲げ加工部、打ち抜き穴を有する金属板を用いた疲労強度に優れた回転体長寿命回転体を提供することを課題とする。
【０００９】
【課題を解決するための手段】
本発明は、前述の課題を解決するために鋭意検討の結果なされたものであり、自動車用ホイール、プーリー、ギア、キャタピラーの動輪など、回転により繰り返し荷重を受ける重ね隅肉溶接継手、冷間曲げ加工部、打ち抜き穴の表面に、超音波振動処理を施すことにより、疲労強度に優れた回転体長寿命回転体を提供するものであり、その要旨とするところは、特許請求の範囲に規定した通りの下記内容である。
【００１０】
（１）２枚の金属板を重ね合わせて端部を溶接した重ね隅肉溶接継手を有する回転体であって、該重ね隅肉溶接継手の止端部の周囲に、超音波衝撃処理によって形成された幅１〜５ｍｍの圧痕を有し、該超音波衝撃処理を施した止端部における止端半径が１ｍｍ以上であることを特徴とする疲労強度に優れた長寿命回転体。
ここに、超音波衝撃処理とは、超音波振動端子により金属板表面を打撃する処理をいう。
（２）２枚の金属板を重ね合わせて端部を溶接した重ね隅肉溶接継手を有する回転体であって、該重ね隅肉溶接継手のルート部の金属板表面または表裏面に、超音波衝撃処理によって形成された幅１〜５ｍｍの圧痕を有することを特徴とする疲労強度に優れた長寿命回転体。
【００１１】
（３）金属板の冷間曲げ加工部を有する回転体であって、該冷間曲げ加工部の引張側表面に超音波衝撃処理を施すことによって、該引張側表面の表面硬さが非処理部と比較して１０％以上増加しており、該冷間曲げ加工部の引張残留応力が引張強度の５０％以下から圧縮の範囲であることを特徴とする疲労強度に優れた長寿命回転体。
（４）金属板の冷間曲げ加工部を有する回転体であって、該冷間曲げ加工部の圧縮側表面に超音波衝撃処理を施すことによって、該圧縮側表面が中心線平均粗さＲａ（ＪＩＳ Ｂ ０６０１）で１０μｍ以下に平滑化されており、該引張側表面の表面硬さが非処理部と比較して１０％以上増加しており、該冷間曲げ加工部の引張残留応力が引張強度の５０％以下から圧縮の範囲であることを特徴とする疲労強度に優れた長寿命回転体。
【００１２】
（５）打ち抜き穴を有する金属板の回転体であって、該打ち抜き穴の端面に超音波衝撃処理を施すことによって、該打ち抜き穴端面の表面のノッチが中心線平均粗さＲａで１０μｍ以下に平滑化されており、該打ち抜き穴端面に硬さ４００Ｈｖ以上の硬化組織がなく、該打ち抜き穴端面の表面から発生した２００μｍ以下の微細な亀裂が、元の長さの５０％以下の深さまで扁平化していることを特徴とする疲労強度に優れた長寿命回転体。
（６）前記金属板の引張強度が４００Ｎ／ｍｍ２以上の鋼材であることを特徴とする（１）ないし（５）のいずれか１項に記載の疲労強度に優れた長寿命回転体。
（７）重ね隅肉溶接継手、冷間曲げ加工部、および／または打ち抜き加工部を有する金属板製回転体の製造方法において、溶接継手の止端部、ルート部、金属板の冷間加工部、打ち抜き加工部等の被処理部の形状に応じた、ピンの先端が凸状または凹状となった超音波振動端子を用いて、超音波衝撃処理を施すことを特徴とする疲労強度に優れた長寿命回転体の製造方法。
【００１３】
【発明の実施の形態】
自動車用ロードホイールを例として、本発明の実施形態について、図１乃至図６を用いて詳細に説明する。
図１は、本発明の実施形態である自動車用ロードホイールの側面図である。
図１の自動車用ロードホイールは、鋼板やアルミ板を打ち抜き加工を含むプレス成形加工により加工されたホイール・ディスク材と、ロール成形されたホイール・リム材を溶接して製造され、１は打ち抜き穴を示している。
以下、金属板とは、鋼板やアルミニウム合金板を含む金属製の板をいう。
【００１４】
図２は、本発明の一つの実施形態である自動車用ロードホイールの断面図であり、図１のＡ−Ａ´断面を示している。
図２において、１は金属板をプレスにより打ち抜いた打ち抜き穴であり、２は金属板を冷間にてプレス成形加工されたいわゆるハット部であり、曲げ加工成分を有することから本発明の冷間曲げ加工部に相当するものであり、３は２枚の金属板を重ね合わせた端部を溶接する重ね隅肉溶接継手部を示す。
自動車の走行中の繰り返し荷重によって、これらの溶接部、冷間曲げ加工部、および、打ち抜き穴に応力集中が発生し易く、これらの部分の疲労強度が最も小さくなるため、この部分に超音波衝撃処理を行うことによって疲労強度を著しく向上させることができる。
【００１５】
図２における４が超音波振動端子を示しており、本発明に使用する超音波振動の発生装置は、発振機により発振され、トランスデューサにより１９ｋＨｚ〜６０ｋＨｚの機械的振動に変換され、ウェーブガイドにてその振幅を増幅させることにより、φ２ｍｍ〜６ｍｍのピンからなる超音波振動端子を２０〜４０μｍの振幅で振動させることによって、打撃部の表面の平滑性に優れた深さ数百μｍ程度の圧痕を形成することができる。この超音波振動発生装置は、以下の実施形態にも共通して用いることができる。
【００１６】
図３は、２枚の金属板の重ね隅肉溶接継手部を示す図であり、図２における３の詳細図である。
図３において、６、７は２枚の金属板であり、９が止端部、１０がルート部を示し、止端部９における曲率半径ρが止端半径、その角度θは止端角を示す。
本発明における回転体（例えば自動車用ロードホイール）は、この重ね隅肉継手の止端部９の周囲に、超音波衝撃処理によって形成された幅１〜５ｍｍの圧痕を有しており、該超音波衝撃処理を施した止端部における止端半径ρが１ｍｍ以上である。
【００１７】
前述の超音波振動端子によって止端部９の周囲を打撃することによって幅１〜５ｍｍの圧痕を形成し、止端部における止端半径ρを１ｍｍ以上とすることにより、止端部９の応力集中を緩和するとともに、引張残留応力を圧縮残留応力に変えることができるので回転体の疲労強度を著しく向上させることができる。
本発明における回転体（例えば自動車用ロードホイール）は、この重ね隅肉継手のルート部１０の金属板表面または表裏面に、超音波衝撃処理によって形成された幅１〜５ｍｍの圧痕を有する。
【００１８】
前述の超音波振動端子によってルート部１０の金属板表面または表裏面を打撃することによって幅１〜５ｍｍの圧痕を形成し、ルート部１０の応力集中を緩和することができるので回転体の疲労強度を著しく向上させることができる。
図４は、金属板の冷間曲げ加工部を示しており、図２における２の拡大詳細図である。
図４において、４、４´は本発明に用いる超音波振動端子を示し、回転体の冷間曲げ加工部（例えばホイールのハット部）の表裏面から超音波振動を付与することにより、冷間曲げ加工部の引張側表面である凸面および圧縮側表面である凹面の表面硬さが非処理部と比較して１０％以上増加しており、冷間曲げ加工部の引張残留応力が引張強度の５０％以下から圧縮の範囲となっている。
【００１９】
この結果、冷間曲げ加工部の疲労強度を著しく向上させることができる。
また、冷間曲げ加工部の圧縮側表面である凹面のみを打撃することによって、圧縮側表面が中心線平均粗さＲａで１０μｍ以下に平滑化されるとともに引張側の残留応力が引張強度の５０％以下に緩和され、また、使用時に人目に触れる表面側に処理痕を残さないので、意匠性を維持したまま疲労強度を向上させることができる。
なお、金属板表面の凹面を打撃する超音波振動端子の先端を凸型とし、金属板表面の凸面を打撃する超音波振動端子の先端を金属板表面の凸面より大きな曲率半径の凹型にすることによって（ただし、図２および図４では超音波振動端子４’の先端の曲率半径は誇張されている。）、金属板表面に超音波振動端子の先端がならい易いので、表面硬さと引張残留応力の軽減効果をさらに高めることができる。
【００２０】
図５および図６は、金属板の打ち抜き穴部に超音波衝撃処理を施す状況を示すもので、図５は図２の部分拡大図、図６はその斜視図である。
図５において、４´は本発明に用いる超音波振動端子を示し、回転体の打ち抜き穴部５（例えばホイールの打ち抜き穴部）の端面に超音波振動を付与することにより、打ち抜き穴端面の表面のノッチが中心線平均粗さＲａで１０μｍ以下に平滑化されており、該打ち抜き穴端面に硬さ４００Ｈｖ以上の硬化組織がなく、該打ち抜き穴端面の表面から発生した２００μｍ以下の微細な亀裂が、元の長さの５０％以下の深さまで扁平化している。
この結果、打ち抜き穴部の疲労強度を著しく向上させることができる。
なお、打ち抜き穴端面を打撃する超音波振動端子の先端を凹型にすることによって、打ち抜き穴端面に超音波振動端子の先端がならい易いので、ノッチの平坦化、硬化組織の除去、および、微細亀裂の扁平化効果をさらに高めることができる。
また、超音波衝撃処理のような残留応力を与える手法は、適用する材料が高強度材の方が低強度材と比較して効果が得られやすい。これは、高強度材の方が導入された残留応力が付加される外力によって再配分されにくいという特性によるものである。
【００２１】
図６において、左右の超音波振動端子４´を上下にずらして配置することによって、左右の超音波振動端子４´が相互に干渉することがないので超音波打撃処理を効率的に行うことができる。
以上の実施形態は、自動車用ロードホイールを例にとって説明したが、本発明は、プーリー、ギア、キャタピラーの動輪など、回転により繰り返し荷重を受ける重ね隅肉溶接継手、冷間曲げ加工部、打ち抜き穴を有する金属板を用いた回転体に広く適用できるものである。
【００２２】
【実施例】
本発明における鋼板製の自動車用ロードホイールの実施例により、本発明の効果を説明する。
自動車用の１３インチのロードホイールについて、処理方法を変えてその疲労強度を比較した。なお、ここで使用したホイール・ディスク材は、板厚３．２ｍｍ、強度６９０Ｎ／ｍｍ２および板厚４．０ｍｍ、強度３３０Ｎ／ｍｍ２の素材から加工したものである。
疲労試験は回転曲げモーメント負荷にて行った。繰り返し速度は７００ｒｐｍ、ボルト締め付けトルク９８Ｎｍ、試験モーメントは１．４７ｋＮｍである。
また、処理前の初期き裂としては、人工的に打ち抜き孔端部に深さ２００μｍのノッチを入れ、試験後に当該部分を切り出して、き裂長さを計測した。
【００２３】
【表１】

Figure 2004169063
表１に結果を示す。
Ｎｏ．１は、発明例であり、曲げ加工部の表裏面、打ち抜き穴端面、重ね隅肉溶接継手部とも先端が凸型の超音波振動端子を用いて打撃処理を行ったので、超音波衝撃処理を行った鋼板表面は平滑化されており、残留応力も圧縮残留応力となっているので疲労寿命は長くなっており評価は「ＯＫ」（良好）だった。
Ｎｏ．２、Ｎｏ．３は、発明例であり、曲げ加工部の表裏面、および重ね隅肉継手部は先端が凸型の超音波振動端子を用いて打撃処理を行い、打ち抜き穴端面は、凹型の超音波振動端子を用いて打撃処理を行ったので、超音波衝撃処理を行った鋼板表面がさらに平滑化され、疲労寿命はさらに長くなっており、評価は「ＯＫ」（良好）だった。
なお、Ｎｏ．１〜Ｎｏ．３の発明例においては、超音波打撃処理を施した鋼板表面の表面硬さ（ビッカース硬度）は、非処理部と比較して約３０％増加した。また、打ち抜き穴端面に硬さ４００Ｈｖ以上の硬化組織がなく、打ち抜き穴端面の表面に導入した２００μｍのノッチが、元の長さの約３０％の深さまで扁平化した。また、溶接部での処理痕も確認できる。
【００２４】
Ｎｏ．４は比較例であり、加工後の処理を何も行っていないので加工面は粗く、残留応力は引張り残留応力となっている部分が多いため、疲労寿命は短くなっており、評価は「ＮＧ」（不良）だった。
Ｎｏ．５は比較例であり、加工後の打ち抜き穴の端面にグラインダー処理を施したので表面の平滑性は向上しているが、残留応力は改善されていないので疲労寿命は短くなっており、評価は「ＮＧ」（不良）だった。
Ｎｏ．６は比較例であり、加工後の曲げ加工部表面にショットピーニング処理を施したので表面の平滑性も、残留応力も改善しており、疲労寿命は長くなっているが、他の部分に対しては何もしていないので、本発明の半分以下に留まっており、評価は「ＮＧ」（不良）だった。
Ｎｏ．７は、ホイール・ディスク材の強度が３３０Ｎ／ｍｍ２の実施例であり、曲げ加工部の表裏面、重ね隅肉溶接継手部とも先端が凸型の超音波振動端子を用いて打撃処理を行い、打ち抜き穴端面は、凹型の超音波振動端子を用いて打撃処理を行ったが、超音波衝撃処理を行った鋼板表面がさらに平滑化されて、長寿命が得られており、評価は「ＯＫ」（良好）であった。
【００２５】
【発明の効果】
本発明によれば、自動車用ロードホイール、プーリー、ギア、キャタピラーの動輪など、回転により繰り返し荷重を受ける重ね隅肉溶接継手、冷間曲げ加工部、打ち抜き穴の表面に超音波振動処理を施すことにより疲労強度に優れた回転体長寿命回転体を提供することができ、産業上有用な著しい効果を奏する。
【図面の簡単な説明】
【図１】本発明の一つの実施形態である自動車用ホイールの側面図である。
【図２】図１のＡ−Ａ断面図である。
【図３】２枚の金属板の重ね隅肉溶接継手部を示す拡大図で説明する図である。
【図４】金属板の冷間曲げ加工部への超音波衝撃処理の状況を説明する図である。
【図５】金属板の打ち抜き穴部への超音波衝撃処理の状況を部分拡大図で説明する図である。
【図６】図５の状況を斜視図で説明する図である。
【符号の説明】
１：打ち抜く穴、 ２：冷間曲げ加工部、 ３：重ね隅肉継手部、
４：超音波振動端子（先端部：凸型）、
４´：超音波振動端子（先端部：凹型）、 ５：打ち抜き穴端面、
６、７：金属板、 ８：溶接金属、９：止端部、１０：ルート部[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a long-life rotating body using a metal plate and having excellent fatigue strength, and a method for manufacturing the same.
For example, road wheels for automobiles, pulleys, gears, driving wheels of caterpillars, lap fillet welded joints that receive repeated loads due to rotation, cold-bent parts, long-life rotating bodies excellent in fatigue strength having punched holes and the like, and the like. It relates to a manufacturing method.
[0002]
[Prior art]
Rotating bodies, such as road wheels for automobiles, pulleys, gears, and driving wheels of caterpillars, which are subjected to repeated loads due to rotation, have weak points in metal fatigue such as lap fillet welded joints, cold-bent parts, and punched holes.
Conventional methods for improving the weld bead shape and fatigue strength by post-processing such as welding, cold bending, and punching include (1) grinding, (2) TIG dressing, (3) shot peening, and the like. (4) Hammer peening has been used. According to these methods, the shape of a weld toe portion serving as a stress concentration portion is shaped to reduce the stress concentration, or the residual stress is changed to improve the fatigue strength. However, these methods also have the following problems.
[0003]
Here, the grinding and the TIG dressing are techniques for improving the fatigue strength by shaping the shape of the stress concentration portion into a shape with less stress concentration. However, these are effective in improving the fatigue strength of lap fillet welded joints and punched holes, but have no effect on cold-bending parts, have extremely low work efficiency, and are not suitable for mass production. Not suitable for use. Further, in grinding, there is also a problem that processing skill is required, for example, when a direction in which a tooth is applied is perpendicular to a direction in which a stress is applied, a processing mark in which a fatigue crack is easily propagated may be formed.
Incidentally, residual stress is generally introduced into the weld by local thermal expansion due to welding heat input and thermal contraction due to subsequent cooling. Also, a large residual stress due to plastic deformation exists in the cold-worked portion. Such residual stress is one of the major factors that lower the fatigue strength.
Therefore, as another means for improving the fatigue strength, a method such as shot peening or hammer peening in which a compressive residual stress is generated or a tensile residual stress is reduced to increase the fatigue strength is known. The shot peening process is a method in which a large number of steel balls of less than 1 mm are hit at a portion serving as a starting point of fatigue crack generation to apply a compressive residual stress. Hammer peening is a method of operating a pin using compressed air or the like and hitting a processing unit.
[0004]
However, shot peening requires a huge machine and requires a chamber when used, so that it is still inefficient for use in mass production, and requires various utilities. In addition, since the place selectivity of processing only necessary portions is remarkably inferior, it cannot be used when design is required.
In addition, hammer peening has a disadvantage in that it has a large recoil and gives too much plastic deformation, so that it is difficult to use a thin plate.
In addition, in the case of hammer peening, machining is performed on the joint part at a low frequency of several Hz, so the surface of the processed surface is severely uneven, and the concave part becomes a stress concentration part and becomes the starting point of fatigue cracking, so the processing result is stable However, there has been a problem that the fatigue strength of the entire joint may sometimes be rather lowered.
[0005]
Further, it is known that the shape of the weld toe can be improved or the tensile residual stress can be reduced by heating and remelting the weld metal. However, this method also has a problem that the efficiency is extremely low, and the effect is not so large.
[0006]
As described above, it is difficult to adopt the conventional fatigue strength improving technology for rotating bodies such as automobile wheels, and even if it can be used, the fatigue strength improvement margin remains at a low level. Therefore, have been addressed by increasing the strength of the material, susceptibility to fatigue punched end face, the strength of the steel material becomes 600N / mm 2 or higher grade, since it becomes abruptly high, fatigue improvement effect peaked There was a problem that it would.
As a conventional technique relating to a method of improving fatigue strength by applying ultrasonic vibration to a welded joint, for example, US Pat. No. 6,171,415 discloses a welded seam heated by a welding arc. A method of applying ultrasonic vibrations along the line is disclosed.
However, this prior art is based on the premise that ultrasonic vibration is applied to a high-temperature material immediately after welding, and a specific object and processing range to be hit with an ultrasonic vibrator as proposed by the present invention. There is no disclosure.
[0007]
[Patent Document 1]
US Patent No. 6,171,415
[Problems to be solved by the invention]
The present invention solves the problems of the prior art as described above, such as automobile wheels, pulleys, gears, caterpillar driving wheels, etc., lap fillet welded joints that receive repeated loads due to rotation, cold bending parts, punched holes It is an object of the present invention to provide a rotating body having a long life and excellent in fatigue strength using a metal plate having the following.
[0009]
[Means for Solving the Problems]
The present invention has been made as a result of intensive studies in order to solve the above-mentioned problems, and includes lap fillet welded joints that receive repeated loads due to rotation, such as automobile wheels, pulleys, gears, and caterpillar driving wheels, and cold bending. The processed part, the surface of the punched hole, by performing ultrasonic vibration treatment, to provide a rotating body long life rotating body excellent in fatigue strength, the gist of which is as defined in the claims It is the following contents.
[0010]
(1) A rotating body having a lap fillet welded joint in which two metal plates are overlapped and their ends welded, and formed around the toe of the lap fillet weld joint by ultrasonic impact treatment. A long-life rotating body excellent in fatigue strength, characterized in that it has an indentation of 1 to 5 mm in width and a toe radius at a toe portion subjected to the ultrasonic impact treatment is 1 mm or more.
Here, the ultrasonic impact treatment refers to a treatment in which the surface of the metal plate is hit with an ultrasonic vibration terminal.
(2) A rotating body having a lap fillet welded joint in which two metal plates are overlapped and their ends are welded, and an ultrasonic wave is applied to the metal plate surface or the front and back surfaces of the root portion of the lap fillet weld joint. A long-life rotating body having excellent fatigue strength, having indentations having a width of 1 to 5 mm formed by impact treatment.
[0011]
(3) A rotating body having a cold-bent portion of a metal plate, wherein the surface hardness of the tensile-side surface is untreated by subjecting the tensile-side surface of the cold-bent portion to ultrasonic impact treatment. A long-life rotating body excellent in fatigue strength, characterized in that the tensile residual stress of the cold-bent part is in the range of 50% or less of the tensile strength to the compression strength, wherein .
(4) A rotating body having a cold-bending portion of a metal plate, wherein the compression-side surface of the cold-bending portion is subjected to ultrasonic impact treatment so that the compression-side surface has a center line average roughness Ra. According to (JIS B 0601), the surface hardness of the tensile side surface is increased by 10% or more as compared with the untreated portion, and the tensile residual stress of the cold bending portion is reduced to 10 μm or less. A long-life rotating body having excellent fatigue strength, which is in the range of 50% or less of tensile strength to compression.
[0012]
(5) A rotating body of a metal plate having a punched hole, wherein the end face of the punched hole is subjected to ultrasonic impact treatment so that the notch on the end face of the punched hole is reduced to a center line average roughness Ra of 10 μm or less. The surface of the punched hole has no hardened structure with a hardness of 400 Hv or more, and fine cracks of 200 μm or less generated from the surface of the punched hole are flattened to a depth of 50% or less of the original length. A long-life rotating body with excellent fatigue strength characterized by the fact that
(6) The long-life rotating body having excellent fatigue strength according to any one of (1) to (5), wherein the metal plate is a steel material having a tensile strength of 400 N / mm 2 or more.
(7) In a method for manufacturing a metal plate rotating body having a lap fillet welded joint, a cold-bent portion, and / or a punched portion, a toe portion of the welded joint, a root portion, and a cold-formed portion of the metal plate. According to the shape of the part to be processed, such as a punched part, the tip of the pin is subjected to ultrasonic shock treatment using a convex or concave ultrasonic vibration terminal, and has excellent fatigue strength. Manufacturing method of long life rotating body.
[0013]
BEST MODE FOR CARRYING OUT THE INVENTION
An embodiment of the present invention will be described in detail with reference to FIGS. 1 to 6 by taking an automobile road wheel as an example.
FIG. 1 is a side view of an automobile road wheel according to an embodiment of the present invention.
The automobile road wheel of FIG. 1 is manufactured by welding a wheel disc material processed by press forming including a punching process to a steel plate or an aluminum plate and a roll-formed wheel rim material, and 1 is a punched hole. Is shown.
Hereinafter, a metal plate refers to a metal plate including a steel plate or an aluminum alloy plate.
[0014]
FIG. 2 is a cross-sectional view of an automobile road wheel according to one embodiment of the present invention, and shows a cross section taken along line AA ′ of FIG. 1.
In FIG. 2, reference numeral 1 denotes a punched hole formed by punching a metal plate by a press, and reference numeral 2 denotes a so-called hat portion which is formed by press-forming a metal plate in a cold state. 3 corresponds to a lap fillet welded joint for welding an end portion where two metal plates are overlapped.
Due to the repeated load during running of the automobile, stress concentration tends to occur in these welded parts, cold-bent parts, and punched holes, and the fatigue strength of these parts is minimized. By performing the treatment, the fatigue strength can be significantly improved.
[0015]
Reference numeral 4 in FIG. 2 denotes an ultrasonic vibration terminal, and the ultrasonic vibration generator used in the present invention is oscillated by an oscillator, converted into mechanical vibration of 19 kHz to 60 kHz by a transducer, and transmitted by a waveguide. By amplifying the amplitude, the ultrasonic vibration terminal composed of a pin having a diameter of 2 mm to 6 mm is vibrated with an amplitude of 20 to 40 μm, so that an indentation having a depth of about several hundred μm excellent in the smoothness of the surface of the hitting portion is obtained. Can be formed. This ultrasonic vibration generator can be commonly used in the following embodiments.
[0016]
FIG. 3 is a view showing a lap fillet weld joint of two metal plates, and is a detailed view of 3 in FIG. 2.
3, 6 and 7 are two metal plates, 9 is a toe, 10 is a root, a radius of curvature ρ at the toe 9 is a toe radius, and an angle θ is a toe angle. Show.
The rotating body (for example, an automobile road wheel) according to the present invention has an indentation of 1 to 5 mm in width formed by ultrasonic impact treatment around the toe 9 of the lap fillet joint. The toe radius ρ at the toe portion subjected to the sonic impact treatment is 1 mm or more.
[0017]
By hitting the periphery of the toe 9 with the above-described ultrasonic vibration terminal to form an indent having a width of 1 to 5 mm, and by setting the toe radius ρ at the toe to 1 mm or more, the stress of the toe 9 is increased. Since the concentration can be reduced and the tensile residual stress can be changed to the compressive residual stress, the fatigue strength of the rotating body can be significantly improved.
The rotating body (for example, a road wheel for automobiles) according to the present invention has indentations having a width of 1 to 5 mm formed on the metal plate surface or front and rear surfaces of the root portion 10 of the lap fillet joint by ultrasonic impact treatment.
[0018]
By hitting the metal plate surface or the front and back surfaces of the root portion 10 with the above-described ultrasonic vibration terminal, an indent having a width of 1 to 5 mm is formed, and stress concentration on the root portion 10 can be reduced, so that the fatigue strength of the rotating body Can be significantly improved.
FIG. 4 shows a cold-bending portion of a metal plate, and is an enlarged detailed view of 2 in FIG.
In FIG. 4, reference numerals 4 and 4 'denote ultrasonic vibration terminals used in the present invention. The ultrasonic vibration terminals are applied from the front and back surfaces of a cold-bending portion (for example, a hat portion of a wheel) of a rotating body to provide a cold vibration terminal. The surface hardness of the convex surface, which is the tensile side surface, and the concave surface, which is the compression side surface, of the bent portion is increased by 10% or more as compared with the untreated portion, and the tensile residual stress of the cold bent portion is lower than the tensile strength. The compression range is from 50% or less.
[0019]
As a result, the fatigue strength of the cold bending part can be significantly improved.
Further, by hitting only the concave surface which is the compression side surface of the cold-bending portion, the compression side surface is smoothed to a center line average roughness Ra of 10 μm or less, and the residual stress on the tension side is reduced by 50%. % Or less, and since no processing marks are left on the surface side that is exposed to human eyes during use, fatigue strength can be improved while maintaining designability.
In addition, the tip of the ultrasonic vibration terminal that hits the concave surface of the metal plate surface has a convex shape, and the tip of the ultrasonic vibration terminal that hits the convex surface of the metal plate surface has a concave shape with a larger radius of curvature than the convex surface of the metal plate surface. (However, in FIGS. 2 and 4, the radius of curvature of the tip of the ultrasonic vibration terminal 4 'is exaggerated.) Since the tip of the ultrasonic vibration terminal is easy to follow the surface of the metal plate, the surface hardness and the tensile residual stress are increased. Can be further enhanced.
[0020]
FIGS. 5 and 6 show a situation in which ultrasonic impact processing is performed on a punched hole of a metal plate. FIG. 5 is a partially enlarged view of FIG. 2 and FIG. 6 is a perspective view thereof.
In FIG. 5, reference numeral 4 'denotes an ultrasonic vibration terminal used in the present invention, and ultrasonic vibration is applied to an end face of a punched hole 5 (for example, a punched hole of a wheel) of a rotating body, so that a surface of the punched hole end face is provided. Are smoothed to a center line average roughness Ra of 10 μm or less, and there is no hardened structure having a hardness of 400 Hv or more on the end face of the punched hole, and a fine crack of 200 μm or less generated from the surface of the end face of the punched hole. And flattened to a depth of 50% or less of the original length.
As a result, the fatigue strength of the punched hole can be significantly improved.
In addition, by making the tip of the ultrasonic vibration terminal that strikes the punched hole end face concave, the tip of the ultrasonic vibration terminal can easily follow the punched hole end face, so that the notch is flattened, the hardened structure is removed, and micro cracks are formed. Can further enhance the flattening effect.
In addition, in a method of applying a residual stress such as an ultrasonic impact treatment, an effect is easily obtained when a high-strength material is applied as compared with a low-strength material. This is due to the characteristic that the high-strength material is less likely to be redistributed by the external force to which the introduced residual stress is applied.
[0021]
In FIG. 6, by disposing the left and right ultrasonic vibration terminals 4 ′ vertically displaced, the left and right ultrasonic vibration terminals 4 ′ do not interfere with each other, so that the ultrasonic impact processing can be performed efficiently. it can.
Although the above embodiments have been described by taking an automobile road wheel as an example, the present invention relates to pulleys, gears, caterpillar driving wheels, and other lap fillet welded joints that receive repeated loads due to rotation, cold-bent parts, punched holes. It can be widely applied to a rotating body using a metal plate having
[0022]
【Example】
The effect of the present invention will be described with reference to an example of an automobile road wheel made of a steel plate according to the present invention.
The fatigue strength of 13-inch road wheels for automobiles was compared by changing the treatment method. Here, using the wheel disc material is to plate thickness 3.2 mm, strength 690n / mm 2 and thickness 4.0 mm, from the strength 330N / mm 2 material was processed.
The fatigue test was performed under a rotating bending moment load. The repetition rate is 700 rpm, the bolt tightening torque is 98 Nm, and the test moment is 1.47 kNm.
In addition, as an initial crack before the treatment, a notch having a depth of 200 μm was artificially formed at the end of the punched hole, and the portion was cut out after the test to measure the crack length.
[0023]
[Table 1]
Figure 2004169063
Table 1 shows the results.
No. 1 is an example of the invention, in which the front and back surfaces of the bent portion, the punched hole end surface, and the lap fillet weld joint portion were subjected to the impact treatment using an ultrasonic vibration terminal having a convex tip, so that the ultrasonic impact treatment was performed. Since the surface of the steel sheet was smoothed and the residual stress was the compressive residual stress, the fatigue life was long and the evaluation was "OK" (good).
No. 2, No. Reference numeral 3 denotes an example of the invention, in which the front and back surfaces of the bent portion and the fillet joint portion are subjected to a hitting process using an ultrasonic vibration terminal having a convex tip, and the end surface of the punched hole is provided with a concave ultrasonic vibration terminal. , The surface of the steel sheet subjected to the ultrasonic impact treatment was further smoothed, the fatigue life was further extended, and the evaluation was "OK" (good).
In addition, No. 1 to No. In the invention example of No. 3, the surface hardness (Vickers hardness) of the steel sheet surface subjected to the ultrasonic impact treatment was increased by about 30% as compared with the non-treated part. Further, there was no hardened structure having a hardness of 400 Hv or more on the end face of the punched hole, and the notch of 200 μm introduced into the surface of the end face of the punched hole was flattened to a depth of about 30% of the original length. Also, processing traces at the welded portions can be confirmed.
[0024]
No. No. 4 is a comparative example. Since no processing was performed after the processing, the processed surface was rough, and the residual stress was often a tensile residual stress. Therefore, the fatigue life was short, and the evaluation was "NG". (Bad).
No. 5 is a comparative example, in which the end surface of the punched hole after processing was subjected to a grinder treatment, so that the surface smoothness was improved, but the residual stress was not improved, so the fatigue life was shortened. "NG" (bad).
No. Reference numeral 6 is a comparative example, in which shot peening was applied to the surface of the bent portion after processing, so that the surface smoothness and residual stress were also improved, and the fatigue life was longer. Nothing was done, so it was less than half of the present invention, and the evaluation was "NG" (poor).
No. 7 is an embodiment in which the strength of the wheel / disk material is 330 N / mm 2. Both the front and back surfaces of the bent portion and the lap fillet weld joint portion are subjected to impact processing using an ultrasonic vibration terminal having a convex end. The end face of the punched hole was hit with a concave ultrasonic vibration terminal, but the surface of the steel sheet subjected to the ultrasonic shock treatment was further smoothed, and a long life was obtained. "(It was good.
[0025]
【The invention's effect】
According to the present invention, ultrasonic vibration treatment is applied to the surfaces of lap fillet welded joints, cold-bent parts, and punched holes that repeatedly receive a load due to rotation, such as road wheels for automobiles, pulleys, gears, and driving wheels of caterpillars. As a result, it is possible to provide a rotating body having a long life and excellent fatigue strength.
[Brief description of the drawings]
FIG. 1 is a side view of an automobile wheel according to one embodiment of the present invention.
FIG. 2 is a sectional view taken along line AA of FIG.
FIG. 3 is an enlarged view showing a fillet weld joint portion of two metal plates.
FIG. 4 is a diagram for explaining the state of an ultrasonic impact process on a cold bending portion of a metal plate.
FIG. 5 is a diagram illustrating a state of an ultrasonic impact process on a punched hole of a metal plate in a partially enlarged view.
6 is a diagram illustrating the situation of FIG. 5 in a perspective view.
[Explanation of symbols]
1: Hole to be punched, 2: Cold bending part, 3: Lap fillet joint part,
4: Ultrasonic vibration terminal (tip: convex),
4 ': ultrasonic vibration terminal (tip: concave), 5: punched hole end face,
6, 7: metal plate, 8: weld metal, 9: toe, 10: root

Claims (7)

２枚の金属板を重ね合わせて端部を溶接した重ね隅肉溶接継手を有する回転体であって、該重ね隅肉溶接継手の止端部の周囲に、超音波衝撃処理によって形成された幅１〜５ｍｍの圧痕を有し、該超音波衝撃処理を施した止端部における止端半径が１ｍｍ以上であることを特徴とする疲労強度に優れた長寿命回転体。A rotating body having a lap fillet welded joint obtained by laminating two metal plates and welding ends thereof, wherein a width formed around the toe of the lap fillet welded joint by an ultrasonic impact treatment is provided. A long-life rotating body having excellent fatigue strength, having an indentation of 1 to 5 mm, and a toe radius at a toe portion subjected to the ultrasonic impact treatment is 1 mm or more. ２枚の金属板を重ね合わせて端部を溶接した重ね隅肉溶接継手を有する回転体であって、該重ね隅肉溶接継手のルート部の金属板表面または表裏面に、超音波衝撃処理によって形成された幅１〜５ｍｍの圧痕を有することを特徴とする疲労強度に優れた長寿命回転体。A rotating body having a lap fillet welded joint in which two metal plates are overlapped and their ends welded, wherein the metal plate surface or the front and back surfaces of the root portion of the lap fillet welded joint is subjected to ultrasonic impact treatment. A long-life rotating body having excellent fatigue strength, having formed indentations having a width of 1 to 5 mm. 金属板の冷間曲げ加工部を有する回転体であって、該冷間曲げ加工部の引張側表面に超音波衝撃処理を施すことによって、該引張側表面の表面硬さが非処理部と比較して１０％以上増加しており、該冷間曲げ加工部の引張残留応力が引張強度の５０％以下から圧縮の範囲であることを特徴とする疲労強度に優れた長寿命回転体。A rotating body having a cold-bending portion of a metal plate, wherein the tensile-side surface of the cold-bending portion is subjected to an ultrasonic impact treatment so that the surface hardness of the tensile-side surface is compared with that of the untreated portion. A long-life rotating body having excellent fatigue strength, characterized in that the tensile residual stress in the cold-bent portion is in the range of 50% or less of the tensile strength to the compression strength. 金属板の冷間曲げ加工部を有する回転体であって、該冷間曲げ加工部の圧縮側表面に超音波衝撃処理を施すことによって、該圧縮側表面が中心線平均粗さＲａで１０μｍ以下に平滑化されており、該引張側表面の表面硬さが非処理部と比較して１０％以上増加しており、該冷間曲げ加工部の引張残留応力が引張強度の５０％以下から圧縮の範囲であることを特徴とする疲労強度に優れた長寿命回転体。A rotating body having a cold-bending portion of a metal plate, wherein the compression-side surface of the cold-bending portion is subjected to ultrasonic impact treatment so that the compression-side surface has a center line average roughness Ra of 10 μm or less. The surface hardness of the surface on the tensile side is increased by 10% or more as compared with the non-treated part, and the tensile residual stress of the cold-bent part is reduced from 50% or less of the tensile strength to the compression strength. A long-life rotating body excellent in fatigue strength, characterized by being within the range of: 打ち抜き穴を有する金属板の回転体であって、該打ち抜き穴の端面に超音波衝撃処理を施すことによって、該打ち抜き穴端面の表面のノッチが中心線平均粗さＲａで１０μｍ以下に平滑化されており、該打ち抜き穴端面に硬さ４００Ｈｖ以上の硬化組織がなく、該打ち抜き穴端面の表面から発生した２００μｍ以下の微細な亀裂が、元の長さの５０％以下の深さまで扁平化していることを特徴とする疲労強度に優れた長寿命回転体。A rotating body of a metal plate having a punched hole, wherein a notch on the end face of the punched hole is smoothed to 10 μm or less in center line average roughness Ra by subjecting the end face of the punched hole to ultrasonic impact treatment. There is no hardened structure with a hardness of 400 Hv or more on the end face of the punched hole, and a fine crack of 200 μm or less generated from the surface of the end face of the punched hole is flattened to a depth of 50% or less of the original length. A long-life rotating body with excellent fatigue strength. 前記金属板の引張強度が４００Ｎ／ｍｍ２以上の鋼材であることを特徴とする請求項１ないし請求項５のいずれか１項に記載の疲労強度に優れた長寿命回転体。The long-life rotating body excellent in fatigue strength according to any one of claims 1 to 5, wherein the metal plate is a steel material having a tensile strength of 400 N / mm 2 or more. 重ね隅肉溶接継手、冷間曲げ加工部、および／または打ち抜き加工部を有する金属板製回転体の製造方法において、溶接継手の止端部、ルート部、金属板の冷間加工部、打ち抜き加工部等の被処理部の形状に応じた、ピンの先端が凸状または凹状となった超音波振動端子を用いて、超音波衝撃処理を施すことを特徴とする疲労強度に優れた長寿命回転体の製造方法。In a method for manufacturing a metal plate rotating body having a lap fillet welded joint, a cold-bending portion, and / or a punched portion, a toe portion of a welded joint, a root portion, a cold-formed portion of a metal plate, and a punching process. Long life rotation with excellent fatigue strength, characterized by applying ultrasonic shock treatment using ultrasonic vibration terminals whose pins have a convex or concave shape according to the shape of the processed part such as the part How to make the body.
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