JP3391919B2 - Manufacturing method of aluminum propeller shaft - Google Patents

Description

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing an aluminum propeller shaft for a vehicle for transmitting power from an engine to driving wheels. 2. Description of the Related Art A propeller shaft P for a vehicle, as shown in FIG.
Shaft 1 and a second shaft connected to the differential side D
A shaft 2, a center universal joint 3 connecting the first and second shafts 1 and 2, and a center bearing for supporting a part of the first shaft 1 near the center universal joint 3 to a vehicle body frame (not shown). And 4. In recent years, the weight of a propeller shaft P for a vehicle has been reduced, and attempts have been made to change the material of the propeller shaft P from steel to aluminum. In this case, if you try to aluminum all parts,
Since aluminum has lower strength than steel, it is necessary to increase the diameter of the shafts 1 and 2. However, such an increase in the shaft diameter causes an increase in the size of the center bearing 4 attached to the outer periphery of the first shaft 1, which increases the peripheral speed so that the permissible rotational speed (DN value) is not satisfied, and also the attachment to the vehicle. There is a problem that space is not satisfied. Therefore, as shown in FIGS. 4 and 5, the present applicant divided the first shaft 1 into an aluminum member 5 on the transmission side T and a steel member 6 on the center bearing 4 side, and joined these surfaces. In addition, a cross serration 7 is formed, and these are engaged with each other, and a cap nut-shaped lock nut 8 is fastened to the outer periphery thereof to be connected (Japanese Patent Application No. 4-320730). According to this configuration, since it is not necessary to increase the size of the steel member 6, the center bearing 4 having the same diameter as the conventional one can be fitted on the outer periphery thereof. Does not occur. [0005] However, it takes time to manufacture the lock nut 8 and to form the cross serrations 7, which increases the manufacturing cost. In addition, it takes a long time to engage the serrations 7 and tighten the lock nut 8. Also, forming the screw 9 for the lock nut 8 on the outer periphery of the aluminum member 5 takes a long processing time due to the large screw size, and also has a problem in mass productivity. Further, since the lock nut 8 is fitted on the outer periphery of the aluminum member 5 and the steel member 6,
As the mounting space increases, the weight also increases, and the merits of aluminum are reduced. SUMMARY OF THE INVENTION An object of the present invention, which has been made in view of the above circumstances, is to provide a method of manufacturing an aluminum propeller shaft capable of connecting an aluminum member and a steel member in a short time and at low cost. In order to achieve the above object, the present invention provides a method for manufacturing an aluminum propeller shaft in which one end surface of an aluminum member is connected to one end surface of a steel member. Forming irregularities for rotation transmission on the end surface, pressing one end surface of the steel member against one end surface of the aluminum member so as to insert it, deforming one end surface of the aluminum member according to the irregularities of the steel member, The outer edge of one end face is pushed backward in the pressing direction of the steel member, and the outer edge of the pushed aluminum member is swaged inward to connect the steel member and the aluminum member. According to the above-described manufacturing method, since the aluminum member and the steel member are cast-in and joined together, there is no need to engage the serrations and tighten the lock nut on the outer periphery of the aluminum member as in the conventional case. The member and the steel member can be joined in a short time and at low cost. In the aluminum propeller shaft manufactured in this manner, the fixing in the rotational direction for transmitting the torque is performed by the engagement of unevenness pressed so as to be cast, and the fixing in the axial direction is performed by caulking the outer edge of the aluminum member. Done by An embodiment of the present invention will be described with reference to the accompanying drawings. As shown in FIG. 3, an aluminum propeller shaft P for a vehicle has a first shaft 1 connected to a transmission side T via a universal joint 10.
And universal joint 1 on differential side D
2, a center universal joint 3 connecting the first and second shafts 1 and 2, and a center universal joint 3
It comprises a center bearing 4 for supporting a part of the first shaft 1 in the vicinity on a vehicle body frame (not shown). The second shaft 2 is provided with a telescopic part 15 formed by inserting a rod body 14 having a spline 13 formed in a pipe body 12 and is freely expandable and contractable in the axial direction.
On the other hand, the first shaft 1 is a universal joint 10
And the center bearing 4
A shaft portion 17 to which is fitted, a yoke 16 and a shaft portion 17
And an aluminum pipe 18 for connecting the same. As shown in FIG. 2, the shaft 17 is divided into an aluminum member 19 and a steel member 20 in the axial direction.
0 are connected to one end face 20a. An aluminum pipe 18 is press-fitted and welded to the end 19 b on the opposite side of the aluminum member 19, and the center bearing 4 is fitted on the outer periphery of the steel member 20. FIG.
Reference numeral 21 denotes a yoke of the center bearing 4. A method of connecting the aluminum member 19 and the steel member 20 will be described with reference to FIG. As shown in the figure, the aluminum member 19 is formed in a cylindrical shape with a bottom, and one end surface 19a is a circular flat surface. On the other hand, one end surface 20 a of the steel member 20 is a circular flat surface having a smaller diameter than the one end surface 19 a of the aluminum member 19. First, as shown in FIG. 1 (a), irregularities 22 for rotation transmission are formed on one end surface 20a of a steel member 20. The irregularities 22 are formed integrally when the steel member 20 is cast or forged. Further, in order to transmit the rotational torque, it is desirable that the irregularities 22 have a shape along the radial direction as shown in FIG. Then, as shown in FIG. 1 (b), one end surface 20a of the steel member 20 is pressed against the one end surface 19a of the aluminum member 19 so as to be cast, and the difference in hardness (strength difference) between the two members 19, 20 is obtained. One end face 1 of aluminum member 19 using
9a is deformed in accordance with the irregularities 22 of the steel member 20, and the outer edge 23 of the one end surface 19a of the aluminum member 19 is pushed backward in the pressing direction A of the steel member 20. At this time, since the outer periphery of the aluminum member 19 is accommodated in a cylindrical mold (not shown), the outer edge 23 is pushed out rearward in the pressing direction A without difficulty. Further, since the aluminum member 19 is appropriately heated so as to be easily deformed, the aluminum member 19 is easily deformed according to the unevenness 22 of the steel member 20. Thereafter, as shown in FIG. 1C, the outer edge 23 of the extruded aluminum member 19 is subjected to inward roll caulking 24 so as to form a flange 25 of the steel member 20.
So that it is covered. Thereby, the aluminum member 19
Axial fixation of the steel member 20 with the steel member 20 is achieved. According to the above-described method, since the aluminum member 19 and the steel member 20 are cast-inserted, the serrations 7, 7 are engaged with each other to form an outer periphery on the outer periphery thereof as in the conventional case shown in FIGS. It is not necessary to tighten the lock nut 8, and the aluminum member 19 and the steel member 20 can be connected in a short time at low cost. In the aluminum propeller shaft P manufactured as described above, the engagement of the irregularities 22 pressed so as to cast the shaft transmits torque in the rotation direction, and the caulking 24 of the outer edge 23 of the aluminum member 19 is moved in the axial direction. Perform fixing. As described above, according to the method of manufacturing an aluminum propeller shaft according to the present invention, an aluminum member and a steel member can be joined in a short time and at low cost.
The number of manufacturing steps and manufacturing costs can be reduced.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an explanatory view showing each step of a method for manufacturing an aluminum propeller shaft according to an embodiment of the present invention. FIG. 2 is a side sectional view of an aluminum propeller shaft manufactured by the above manufacturing method. FIG. 3 is an overall view of an aluminum propeller shaft for a vehicle. FIG. 4 is a side sectional view of a main part of an aluminum propeller shaft manufactured by a conventional manufacturing method. FIG. 5 is an exploded perspective view of FIG. [Description of Signs] 19 Aluminum member 19a One end surface 20 Steel member 20a One end surface 22 Roughness 23 Outer edge 24 Caulking A Pressing direction P Aluminum propeller shaft

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Claims (1)

(1) In a method for manufacturing an aluminum propeller shaft in which one end surface of a steel member is connected to one end surface of an aluminum member, unevenness for rotation transmission is formed on one end surface of the steel member. It is molded, and one end surface of the steel member is pressed into the one end surface of the aluminum member so that the one end surface of the aluminum member is deformed according to the unevenness of the steel member. A method of manufacturing an aluminum propeller shaft in which a steel member and an aluminum member are connected by extruding rearward in a pressing direction and caulking an outer edge of the extruded aluminum member inward.