JP2838680B2 - Method of manufacturing rotating member having ABS rotor - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention
The rotor detected by the sensor in the S-equipped vehicle is
For example, a method of manufacturing a rotating member provided on a hub, a hub bearing, a drive shaft, a front axle shaft, a rear axle shaft, a differential gear, a differential shaft, a transmission (automatic, manual, continuously variable transmission) gear and shafts in an axle portion. About.

[0002]

2. Description of the Related Art An automobile ABS (antilock brake system) includes a rotor provided on a member that rotates integrally with a wheel, and a wheel speed sensor such as a coil for detecting the rotation of the rotor. The rotor is, for example, an axle hub,
It is provided on rotating members such as hub bearings, drive shafts, front axle shafts, rear axle shafts, differential gears, differential shafts, transmission (automatic, manual, continuously variable transmission) gears and shafts.

[0003] A conventional rotor includes a ring-shaped rotor (a front rotor or a rear rotor) 2 formed by sintering, forging, and machined or sheet metal pressed, like a rotating member 1 illustrated in FIG. The rotor 2 is attached to the rotating member 1 by press-fitting the rotating member 1 such as a bearing. This rotor 2 has a large number of teeth 2a in the circumferential direction as shown in FIG.
The teeth 2a are arranged so as to face a wheel speed sensor on the vehicle body side.

[0004]

In the conventional rotor 2 having the above-described structure, a rotor 2 which is formed separately from the rotating member 1 is assembled into the rotating member 1 by press-fitting. The process was complicated and expensive. In addition, there are problems such as difficulty in assembling the rotor 2 to the rotating member 1 with high accuracy, and there is room for improvement.

[0005] Accordingly, an object of the present invention can be manufactured at low cost by a relatively simple process a rotary member having a highly accurate rotor, producing a rotating member having an ABS rotor for reliable vehicle It is to provide a method.

[0006]

SUMMARY OF THE INVENTION The present invention, which has been developed to achieve the above object, comprises a hub, a hub bearing, a drive shaft, a front axle shaft, a rear axle shaft, a differential gear,
It is applied to rotating members such as differential shafts, transmission (automatic, manual, continuously variable transmission) gears and shafts .

The manufacturing method of the present invention is characterized in that a steel material is pressed by hot forging or warm forging in a state where it is easily plastically deformed to form the rotary member main body into a desired product shape and, at the same time, to form the rotor part into a product. A first forging step of forming an outer shape close to the shape, and a cold forming process having a rotor forming surface capable of forming a material formed by the first forging step into a finished dimension after subjecting the material to a predetermined processing. A second forging step of accommodating a forging die and forming a rotor portion having a finished size and shape corresponding to the rotor forming surface by cold forging using the die.

In the above-mentioned processing, before the second forging step is performed, the material is cooled or normalized as necessary,
In a second forging process, which sequentially performs shot blasting and bonderite processing, and thereafter, in a second forging process, only the rotor portion is cold forged (cold coining) using a mold having a rotor molding surface having a finished dimension shape, and the rotor portion is formed. Is formed into a final finished size shape. After the second forging step is completed, the rotary member main body is machined.

In the manufacturing method of the present invention, for example, the outer shape of the material of the rotor portion formed in the first forging step is set to be slightly smaller than the rotor forming surface of the mold used in the second forging step, Upsetting (upsetting) is performed such that when the raw material is pressed in the second forging step, the outer shape of the raw material of the rotor portion expands to a predetermined finished shape toward the rotor molding surface. In this case, the dimensional difference between the outer shape of the material and the molding surface of the rotor is 0.01 mm to 0.5 mm.
mm.

[0010] Alternatively, the outer shape of the material of the rotor portion formed in the first forging process is set to be slightly larger than the rotor forming surface of the mold used in the second forging process, and the material is formed in the second forging process. The ironing process is performed by plastically deforming the outer shape of the material of the rotor portion to a finished size and shape by the rotor molding surface when is pressed. In this case, the dimensional difference between the outer shape of the material and the molding surface of the rotor is 0.01 m.
It is good to make it range from m to 0.5 mm.

[0011]

Embodiments of the present invention will be described below with reference to the drawings. One example of the rotating member 10 shown in FIG. 1 is a steel hub bearing used for a drive system of an automobile. The rotating member 10 has a cylindrical boss 11a.
And a rotating member main body 11 having a disk-shaped flange 11b and an ABS integrally formed on the outer periphery of the boss 11a.
And a rotor section 12 for The material of the rotating member 10 is, for example, a steel material such as nickel-chromium molybdenum steel, chromium molybdenum steel, chromium steel, and carbon steel.

As shown in FIG. 2, the rotor portion 12 has a large number of teeth 12 formed at equal pitches in the circumferential direction of the rotating member 10.
a, and the teeth 12a face a wheel speed sensor (not shown) of an ABS-equipped vehicle. The rotor section 12 may be provided, for example, on a front axle shaft, a rear axle shaft, a drive shaft, or the like in addition to the hub bearing, and may be provided on a member that rotates integrally with the wheels.

The rotating member 10 having the rotor section 12
Is manufactured through a manufacturing process shown in FIG. 3 when the material is tough steel (tempered steel). First, in a material supply step S1, a steel material suitable for the rotating member 10 is cut into a size corresponding to the size of the rotating member 10. And heating step S2
In (2), heating is performed to a temperature suitable for hot forging (or warm forging), that is, a temperature (recrystallization temperature or higher) at which the deformation resistance during forging becomes small. For hot forging, generally 80
Heat above 0 ° C. In warm forging, the material is heated to a lower temperature.

The heated material is stamped in a hot or warm region in a first forging step S3 to form the rotating member main body 11 into a desired product shape,
The rotor section 12 is formed into an outer shape close to the product shape.

After the first forging step S3, in a heat treatment step S4, quenching and tempering or normalizing are performed to improve the material, that is, adjust the austenite grain size and adjust the proeutectoid carbide. After performing the heat treatment step S4, a shot blast step S5 is performed to remove oxides on the surface of the material. Subsequently, in the bonderite step S6, a lubricating film is formed by applying a phosphate to the surface of the material, thereby improving the lubricity between the material and the mold in the second forging step S7 to be performed next.

Then, in a second forging step (cold coining step) S7, cold coining is performed using a mold 20 for cold forging, an example of which is shown in FIG. In FIG. 4, the left half shows the state before pressing and the right half shows the state after pressing. One example of the mold 20 includes a lower mold 21, an upper mold 22, a knockout pin 23, and the like. On the inner surface of the lower mold 21, a rotor forming surface 25 having a predetermined finished size and shape is provided. In the second forging step S7, the rotor forming surface 25
The cold forging of the rotor part 12 is performed by the above.

That is, the material W formed into an outer shape close to the product shape in the first forging step S3 is inserted into the cold forging die 20, and the material is inserted between the lower die 21 and the upper die 22. By pressing the W in the axial direction, a large internal pressure is generated in the material W, and the shape of the rotor molding surface 25 is transferred to the rotor portion 12 of the rotating member 10 to give desired accuracy. FIG. 5 shows a part of the rotor unit 12.

In the forging step S7, the rotor portion 12 is subjected to plastic working by upsetting, ironing, or a combination thereof as described below. For example, the outer shape of the material of the rotor portion 12 formed in the first forging step S3 is set to a size slightly smaller than the final product shape, and when the material W is pressed in the second forging step S7,
Upsetting is performed such that the material outer shape of the rotor portion 12 follows the rotor forming surface 25 by causing plastic flow in the direction in which the material outer shape of the second material 2 expands toward the rotor forming surface 25 of the mold 20. .

In the case of the upsetting as described above, as shown in FIG. 6, the dimensional difference G1 between the outer shape of the material and the rotor molding surface 25 is set to 0.
It is good to set it in the range of 01 mm to 0.5 mm. If the dimensional difference G1 is less than 0.01 mm, it becomes difficult to form the rotor portion 12 to have a desired shape accuracy in the first forging step S3. If the dimensional difference G1 exceeds 0.5 mm, the accuracy of the shape of the rotor portion 12 formed in the second forging step S7 may deteriorate.

Alternatively, the outer shape of the material of the rotor portion 12 formed in the first forging step S3 is made slightly larger than the shape of the final product, and when the material W is pressed in the second forging step S7, 12 material outlines in mold 2
By causing plastic flow in the direction of narrowing by the 0 rotor forming surface 25, the ironing of the rotor portion 12 is performed.

In the case of ironing as described above, FIG.
As shown in (a), the dimensional difference G2 between the outer shape of the material and the rotor molding surface 25 is preferably in the range of 0.01 mm to 0.5 mm. If the dimensional difference G2 is less than 0.01 mm, the accuracy of the shape of the rotor portion 12 formed in the second forging step S7 may deteriorate. If the dimensional difference G2 exceeds 0.5 mm, the material W may not easily enter the rotor forming surface 25, and may not be formed properly.

By setting the dimensional difference (coining amount) as described above in the cold forging step S7, the rotor portion 12 having the same accuracy as that of a conventional sintered molded product or an ABS rotor formed by machining after forging can be formed. can get. FIG.
As shown in (b), a part of the material outer shape is slightly larger than the rotor forming surface 25 and the other part is slightly smaller, and the upsetting and ironing are assembled in the second forging step S7. The combined plastic working may be performed.

The rotating member 10 having the rotor portion 12 thus formed is provided with the knockout pin 2 after the cold forging.
3 and lifted out of the mold 20. After that, in the machining step S8, the rotating member main body 11 is processed into a product shape by the same machining as in the related art.

When the material is a tough steel (non-heat treated steel), air cooling is performed after the first forging step S3 as shown in FIG. Other than that, it is the same as the case of the above-mentioned tempered steel. When the material is carburized steel, as shown in FIG. 9, after performing the first forging step S3, normalizing is performed as necessary. After performing the machining step S8, carburizing and tempering are performed in the heat treatment step S9. Other than that, it is the same as the case of the above-mentioned tempered steel.

FIG. 10 shows an example in which the rotor portion 12 is formed along the outer periphery of the hub bearing boss portion 11a.
Also in this case, the rotor forming surface 25 is provided on the inner surface of the lower die 21, and in the above-described second forging step S7, the shape of the rotor forming surface 25 is changed by upsetting, ironing or plastic working by a combination thereof. The image is transferred to the rotor section 12, and the accuracy of the rotor section 12 is ensured. The manufacturing process in this case is the same as in the above embodiment.

FIG. 11 shows an example in which the rotor portion 12 is formed at the end of the boss portion 11a of the hub bearing. In the forging step S7, the rotor is formed by swaging, ironing, or plastic working combining these. The rotor portion 12 according to the shape of the surface 25 is formed with high precision. The manufacturing process is the same as in the above embodiment.

FIG. 12 shows the flange portion 11 of the hub bearing.
This is an example in which the rotor portion 12 is formed on the outer periphery of the forging step b. In the forging step S7, the rotor portion 12 according to the shape of the rotor forming surface 25 is accurately formed by upsetting, ironing, or plastic working in which these are combined. You. The manufacturing process is the same as in the above embodiment.

FIG. 13 shows the flange portion 11 of the hub bearing.
This is an example in which the rotor portion 12 is formed along the end face b. In the forging step S7, the rotor portion 12 according to the shape of the rotor forming surface 25 is accurately formed by upsetting, ironing, or plastic working combining these. Molded. The manufacturing process is the same as in the above embodiment.

FIG. 14 shows an example in which the rotor part 12 is formed on the end face of the hub bearing boss part 11a. In the forging step S7, the shape of the rotor forming surface 25 is obtained by swaging, ironing or plastic working combining these. Is accurately formed. The manufacturing process is the same as in the above embodiment.

FIG. 15 shows an example in which the rotor portion 12 is formed on the end face of the disk portion of the axle shaft. In the forging step S7, the rotor forming surface 25 is formed by upsetting, ironing or plastic working in which these are combined. The rotor portion 12 according to the shape is precisely formed. The manufacturing process is the same as in the above embodiment.

FIG. 16 shows an example in which the rotor portion 12 is formed on the end surface of the shaft portion of the axle shaft. In the forging step S7, the rotor forming surface 25 is formed into the shape of the rotor forming surface 25 by upsetting, ironing, or plastic working combining these. The corresponding rotor portion 12 is accurately formed. The manufacturing process is the same as in the above embodiment.

FIG. 17 shows an example in which the rotor portion 12 is formed on the outer periphery of the drive shaft. In the forging step S7, the shape of the rotor forming surface 25 is adjusted by upsetting, ironing or plastic working in which these are combined. Rotor part 12
Is molded with high precision. The manufacturing process is the same as in the above embodiment.

[0033]

According to the present invention, it is possible to form a rotating member integrally having an ABS rotor portion at low cost and with high accuracy by a relatively simple process mainly involving forging, and furthermore, a rotating member body. It is possible to obtain a rotating member having a highly reliable rotor such that the dimension setting between the rotor and the rotor portion can be regulated with high precision.

[Brief description of the drawings]

FIG. 1 is a longitudinal sectional view of a rotating member according to an embodiment of the present invention.

FIG. 2 is a sectional view taken along the line II-II in FIG.

FIG. 3 is a flowchart showing a process of manufacturing a rotating member from tempered steel.

FIG. 4 is a cross-sectional view schematically showing a mold for cold-forging the rotating member shown in FIG.

FIG. 5 is a plan view of a rotor unit.

FIG. 6 is a cross-sectional view schematically showing a relationship between a part of a material outer shape and a rotor molding surface.

FIG. 7 is a schematic diagram showing a relationship between a part of the material outer shape and a rotor molding surface.

FIG. 8 is a flowchart showing a process of manufacturing a rotating member from non-heat treated steel.

FIG. 9 is a flowchart showing a process of manufacturing a rotating member from carburized steel.

FIG. 10 is a sectional view of a mold or the like when a rotor portion is provided on the outer periphery of a boss portion of a hub bearing.

FIG. 11 is a sectional view of a mold or the like when a rotor portion is provided at an end of a boss portion of a hub bearing.

FIG. 12 is a sectional view of a mold or the like when a rotor portion is provided on the outer periphery of a flange portion of a hub bearing.

FIG. 13 is a sectional view of a mold or the like when a rotor portion is provided on an end surface of a flange portion of a hub bearing.

FIG. 14 is a sectional view of a mold or the like when a rotor portion is provided on an end surface of a boss portion of a hub bearing.

FIG. 15 is a cross-sectional view of a mold or the like when a rotor portion is provided on an end surface of a disk portion of an axle shaft.

FIG. 16 is a cross-sectional view of a mold and the like when a rotor portion is provided on an end surface of a shaft portion of an axle shaft.

FIG. 17 is a cross-sectional view of a mold and the like when a rotor portion is provided on an outer peripheral portion of a drive shaft.

FIG. 18 is a view showing a conventional rotating member and a rotor.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 ... Rotating member 11 ... Rotating member main body 12 ... Rotor part 20 ... Die 25 ... Rotor molding surface

──────────────────────────────────────────────────続 き Continued on front page (58) Field surveyed (Int.Cl. ⁶ , DB name) B21K 1/02

Claims (3)

(57) [Claims] 1. A manufacturing method for manufacturing a rotating member having a rotor portion in a part of the rotating member body, comprising pressing a steel material by hot forging or warm forging to form the rotating member body. A first forging step of forming the rotor portion into an outer shape close to the product shape at the same time as forming the rotor into a desired product shape; and a rotor forming surface capable of forming the material formed by the first forging step into a finished dimensional shape. A second forging step of accommodating in a mold for cold forging having, and forming a rotor portion having a finished dimension shape corresponding to the rotor molding surface by cold forging using the mold. A method for producing a rotating member having an ABS rotor. 2. The method according to claim 2, wherein the outer shape of the material of the rotor portion formed in the first forging step is slightly smaller than the rotor forming surface of the cold forging die used in the second forging step. When the material is pressed in the forging process, the material outer shape of the rotor portion is expanded to a predetermined finished shape toward the rotor forming surface, and the material outer shape and the rotor before the second forging process are performed. 2. The method for manufacturing a rotating member having an ABS rotor according to claim 1 , wherein the dimensional difference between the molding surfaces is in the range of 0.01 mm to 0.5 mm. 3. The method according to claim 2, wherein the outer shape of the material of the rotor portion formed in the first forging step is slightly larger than the rotor forming surface of the cold forging die used in the second forging step. When the material is pressed in the forging step, the material outer shape of the rotor portion is reduced to a predetermined finished size shape by the rotor forming surface, and the material outer shape and the rotor forming surface before the second forging step is performed. 2. The method for manufacturing a rotating member having an ABS rotor according to claim 1 , wherein a dimensional difference between the two is set within a range of 0.01 mm to 0.5 mm.