JP4775017B2 - Method for manufacturing cylindrical member with protrusion - Google Patents

Method for manufacturing cylindrical member with protrusion Download PDF

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JP4775017B2
JP4775017B2 JP2006032905A JP2006032905A JP4775017B2 JP 4775017 B2 JP4775017 B2 JP 4775017B2 JP 2006032905 A JP2006032905 A JP 2006032905A JP 2006032905 A JP2006032905 A JP 2006032905A JP 4775017 B2 JP4775017 B2 JP 4775017B2
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peripheral surface
outer ring
mandrel
intermediate material
cylindrical member
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JP2007210014A (en
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一登 小林
裕 安田
清司 大塚
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NSK Ltd
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NSK Ltd
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Description

この発明の対象となる突出部を備えた筒状部材は、例えば、車輪支持用ハブユニットを構成する外輪の如く、全体が筒状(一般的には円筒状)で、外周面に、円周方向に間欠的に設けられた突片状の突出部を設けた金属製部材である。本発明は、この様な突出部を備えた筒状部材を、低コストで精度良く加工できる製造方法の実現を図るものである。 The cylindrical member provided with the projecting portion as an object of the present invention is generally cylindrical (generally cylindrical) like an outer ring constituting a wheel support hub unit, and has a circumferential surface on the outer peripheral surface. It is a metal member provided with protruding piece-like protrusions provided intermittently in the direction . The present invention is intended to realize a manufacturing method that can accurately process a cylindrical member having such a protrusion at low cost.

自動車の車輪を構成するホイール1、及び、制動用回転部材であって制動装置であるディスクブレーキを構成するロータ2は、例えば図4に示す様な構造により、懸架装置を構成するナックル3に回転自在に支持している。即ち、このナックル3に形成した円形の支持孔4部分に、車輪支持用ハブユニット5を構成する外輪6を、複数本のボルト7により固定している。一方、この車輪支持用ハブユニット5を構成するハブ8に上記ホイール1及びロータ2を、複数本のスタッド9とナット10とにより結合固定している。又、上記外輪6の内周面には複列の外輪軌道11a、11bを、外周面には結合フランジ12を、それぞれ形成している。この様な外輪6は、この結合フランジ12を上記ナックル3に、上記各ボルト7で結合する事により、このナックル3に対し固定している。   A wheel 1 constituting a wheel of an automobile and a rotor 2 constituting a disc brake as a braking device and a braking device rotate to a knuckle 3 constituting a suspension device, for example, by a structure as shown in FIG. Supports freely. That is, the outer ring 6 constituting the wheel support hub unit 5 is fixed to the circular support hole 4 formed in the knuckle 3 by a plurality of bolts 7. On the other hand, the wheel 1 and the rotor 2 are coupled and fixed to a hub 8 constituting the wheel support hub unit 5 by a plurality of studs 9 and nuts 10. Further, double-row outer ring raceways 11a and 11b are formed on the inner peripheral surface of the outer ring 6, and a coupling flange 12 is formed on the outer peripheral surface. Such an outer ring 6 is fixed to the knuckle 3 by connecting the connecting flange 12 to the knuckle 3 with the bolts 7.

又、上記ハブ8は、ハブ本体13と内輪14とから成る。このうち、ハブ本体13の外周面の一部で、上記外輪6の外端開口から突出した部分に、取付フランジ15を形成している。尚、軸方向に関して「外」とは、自動車への組み付け状態で車両の幅方向外側となる、図4、5の左側を言う。反対に、自動車への組み付け状態で車両の幅方向中央側となる、図4、5の右側を、軸方向に関して「内」と言う。上記ホイール1及びロータ2は、上記取付フランジ15の外側面に、上記各スタッド9とナット10とにより結合固定している。   The hub 8 includes a hub body 13 and an inner ring 14. Among these, a mounting flange 15 is formed on a part of the outer peripheral surface of the hub body 13 and protruding from the outer end opening of the outer ring 6. Note that “outside” with respect to the axial direction refers to the left side of FIGS. On the other hand, the right side in FIGS. 4 and 5, which is the center side in the width direction of the vehicle in the assembled state in the automobile, is referred to as “inside” in the axial direction. The wheel 1 and the rotor 2 are coupled and fixed to the outer surface of the mounting flange 15 by the studs 9 and nuts 10.

又、上記ハブ本体13の外周面の中間部に、上記複列の外輪軌道11a、11bのうちの外側の外輪軌道11aに対向する、内輪軌道16aを形成している。又、同じく内端部に形成した小径段部17に、上記内輪14を外嵌している。この内輪14の外周面には、上記複列の外輪軌道11a、11bのうちの内側の外輪軌道11bに対向する、内輪軌道16bを形成している。この様な内輪14は、上記ハブ本体13の内端部を径方向外方に塑性変形させて形成したかしめ部18により、このハブ本体13に対し固定している。そして、上記各外輪軌道11a、11bと上記各内輪軌道16a、16bとの間に転動体19、19を、それぞれ複数個ずつ転動自在に設けている。尚、図示の例では、上記各転動体19、19として玉を使用しているが、重量の嵩む自動車用のハブユニットの場合には、円すいころを使用する場合もある。又、上記各転動体19、19を設置した円筒状の空間の両端開口部は、それぞれシールリング20a、20bにより密閉している。   Further, an inner ring raceway 16a is formed in the middle portion of the outer peripheral surface of the hub body 13 so as to face the outer ring raceway 11a on the outer side of the double row outer ring raceways 11a, 11b. Further, the inner ring 14 is externally fitted to a small diameter step portion 17 formed at the inner end portion. An inner ring raceway 16b is formed on the outer peripheral surface of the inner ring 14 so as to face the inner outer ring raceway 11b of the double row outer ring raceways 11a and 11b. Such an inner ring 14 is fixed to the hub body 13 by a caulking portion 18 formed by plastic deformation of the inner end portion of the hub body 13 radially outward. A plurality of rolling elements 19, 19 are provided between the outer ring raceways 11a, 11b and the inner ring raceways 16a, 16b, respectively, so as to be able to roll. In the illustrated example, balls are used as the rolling elements 19, 19. However, in the case of a heavy vehicle hub unit, tapered rollers may be used. Further, both end openings of the cylindrical space in which the rolling elements 19 and 19 are installed are sealed with seal rings 20a and 20b, respectively.

更に、図示の例は、駆動輪(FF車の前輪、FR車及びRR車の後輪、4WD車の全車輪)用の車輪支持用ハブユニット5である為、上記ハブ8の中心部に、スプライン孔21を形成している。そして、このスプライン孔21に、等速ジョイント用外輪22の外端面に固設したスプライン軸23を挿入している。これと共に、このスプライン軸23の先端部にナット24を螺合し、更に緊締する事により、上記ハブ本体13を、このナット24と上記等速ジョイント用外輪22との間に挟持している。   Furthermore, since the illustrated example is a wheel support hub unit 5 for driving wheels (front wheels of FF vehicles, rear wheels of FR and RR vehicles, all wheels of 4WD vehicles), A spline hole 21 is formed. A spline shaft 23 fixed to the outer end surface of the constant velocity joint outer ring 22 is inserted into the spline hole 21. At the same time, a nut 24 is screwed to the tip of the spline shaft 23 and further tightened, whereby the hub body 13 is sandwiched between the nut 24 and the constant velocity joint outer ring 22.

次に、図5は、従来から知られている車輪支持用ハブユニットの第2例として、従動輪(FF車の後輪、FR車及びRR車の前輪)用のものを示している。この第2例の車輪支持用ハブユニット5aは、従動輪用である為、ハブ8aを構成するハブ本体13aの中心部にスプライン孔を設けていない。尚、図示の例では、内輪14の内端面を、上記ハブ本体13aの内端部に設けたかしめ部18により抑えているが、上記内輪14の内端面は、上記ハブ本体13aの内端部に螺合したナットにより抑える事もできる。この場合には、上記ハブ本体13aの内端部に、上記ナットを螺合する為の雄ねじ部を設ける。その他の部分の構造及び作用は、上述した第1例の車輪支持用ハブユニット5の場合と同様である。   Next, FIG. 5 shows a second example of a conventionally known wheel support hub unit for a driven wheel (rear wheel of FF vehicle, front wheel of FR vehicle and RR vehicle). Since the wheel support hub unit 5a of the second example is for a driven wheel, a spline hole is not provided at the center of the hub body 13a constituting the hub 8a. In the illustrated example, the inner end surface of the inner ring 14 is suppressed by a caulking portion 18 provided at the inner end portion of the hub main body 13a. However, the inner end surface of the inner ring 14 is the inner end portion of the hub main body 13a. It can also be suppressed by a nut screwed into the nut. In this case, a male screw portion for screwing the nut is provided at the inner end portion of the hub body 13a. The structure and operation of the other parts are the same as in the case of the wheel support hub unit 5 of the first example described above.

ところで、上述した様な各車輪支持用ハブユニット5、5aの場合、何れの構造の場合も、外輪6の外周面中間部に結合フランジ12を、内周面に複列の外輪軌道11a、11bを、それぞれ形成している。この様な各部を加工する為の方法としては、熱間鍛造或いは冷間鍛造等の塑性加工の他、切削加工等が考えられる。但し、加工能率を良好にし、材料の歩留を確保して、コスト低減を図る為には、塑性加工で行なう事が好ましい。又、塑性加工のうちで熱間鍛造は、被加工物を軟らかい状態で加工できる為、成形荷重を小さく抑えられる反面、熱膨張量差等を考慮して、受型と押型との嵌合部の公差を大きくする必要がある等、加工品の形状精度及び寸法精度を確保しにくい。又、熱間鍛造の場合には、表面に脱炭層が生じる為、熱処理により表面を硬化させる必要がある部分の場合には、熱間鍛造の後、上記脱炭層を除去する為の切削加工が必要になる。この切削加工による取り代は或る程度嵩む為、この切削加工により、加工能率が低下するだけでなく材料の歩留も悪化し、上記外輪6の加工コストが嵩む原因になる。   By the way, in the case of each wheel supporting hub unit 5, 5a as described above, in any structure, the coupling flange 12 is provided at the intermediate portion of the outer peripheral surface of the outer ring 6, and the double-row outer ring raceways 11a, 11b are provided on the inner peripheral surface. Are formed respectively. As a method for processing such each part, cutting processing or the like can be considered in addition to plastic processing such as hot forging or cold forging. However, in order to improve the working efficiency, secure the yield of the material, and reduce the cost, it is preferable to carry out plastic working. Moreover, since hot forging can be processed in a soft state among plastic working, the molding load can be kept small, but considering the difference in thermal expansion, etc., the fitting part between the receiving die and the stamping die It is difficult to ensure the shape accuracy and dimensional accuracy of the processed product. In the case of hot forging, a decarburized layer is formed on the surface. Therefore, in the case where the surface needs to be hardened by heat treatment, the cutting process for removing the decarburized layer is performed after hot forging. I need it. Since the machining allowance due to this cutting process increases to some extent, this cutting process not only decreases the processing efficiency but also deteriorates the yield of the material, which increases the processing cost of the outer ring 6.

これらの事を考慮して、上記外周面に結合フランジ12を有する外輪6の加工を、冷間鍛造の1種である側方押し出し加工により造る事が考えられている(特願2004−298585号)。図6は、この側方押し出し加工により、上記外輪6を造る状況を示している。本発明は、この図6に示した様な製造装置により実施される、先発明の側方押し出し加工の改良に関するものであり、本発明と先発明とは共通する部分が多い。そこで、先ず、上記図6により、上記側方押し出し加工を利用して上記外輪6を造る状況に就いて、詳しく説明する。尚、上記図6中、右半部は加工開始直前の状態を、左半部は加工終了直後の状態を、それぞれ示している。先ず、製造装置に就いて説明する。   Considering these things, it is considered that the outer ring 6 having the coupling flange 12 on the outer peripheral surface is manufactured by side extrusion, which is a kind of cold forging (Japanese Patent Application No. 2004-298585). ). FIG. 6 shows a situation in which the outer ring 6 is made by this side extrusion process. The present invention relates to the improvement of the side extrusion process of the prior invention, which is performed by the manufacturing apparatus as shown in FIG. 6, and the present invention and the prior invention have many common parts. First, the situation in which the outer ring 6 is manufactured using the side extrusion processing will be described in detail with reference to FIG. In FIG. 6, the right half indicates the state immediately before the start of processing, and the left half indicates the state immediately after the end of processing. First, the manufacturing apparatus will be described.

プレス加工機のテーブル(図示省略)の上面に載置固定する下板25の上面に、下側保持筒26を固定している。又、この下側保持筒26の下端部内側に抑え板27を固定し、この抑え板27の中心孔28の内側に、円柱状のマンドレル29の基端部(下端部)を支持固定し、この抑え板27の上面でこのマンドレル29の下半部の周囲に、円筒状の下側パンチ30を外嵌している。この下側パンチ30は、加工後の中間素材(第二中間素材)を上記マンドレル29の周囲から抜き出す為のカウンターパンチとしての機能も備えたもので、このマンドレル29の外周面と、上記下側保持筒26の内側に保持された、厚肉円筒状の下側支持ブロック31の内周面との間に、所定量分だけ、昇降自在に設けられている。上記中間素材の取り出し時には、上記下側パンチ30の下側に圧油等の圧力流体を導入して、この下側パンチ30を所定量だけ上昇させ、上記中間素材を押し上げる。   A lower holding cylinder 26 is fixed to the upper surface of the lower plate 25 that is placed and fixed on the upper surface of a table (not shown) of the press machine. Further, a holding plate 27 is fixed inside the lower end portion of the lower holding cylinder 26, and a base end portion (lower end portion) of a cylindrical mandrel 29 is supported and fixed inside the center hole 28 of the holding plate 27, A cylindrical lower punch 30 is fitted around the lower half of the mandrel 29 on the upper surface of the holding plate 27. The lower punch 30 also has a function as a counter punch for extracting the processed intermediate material (second intermediate material) from the periphery of the mandrel 29. The lower punch 30 has an outer peripheral surface of the mandrel 29 and the lower side. A predetermined amount is provided between the inner peripheral surface of the thick cylindrical lower support block 31 held inside the holding cylinder 26 so as to be movable up and down. When the intermediate material is taken out, a pressure fluid such as pressure oil is introduced into the lower side of the lower punch 30 to raise the lower punch 30 by a predetermined amount and push up the intermediate material.

又、上記下側保持筒26の上部内側に、厚肉円筒状の下型32を内嵌固定している。上記下側パンチ30の上部はこの下型32の中心孔33に、密に、且つ、軸方向の変位(昇降)を可能な状態で挿入している。又、この下型32の上面で上記中心孔33の周囲部分に、前記外輪6の外周面に形成すべき結合フランジ12(図4〜5参照)の片半部(前記外輪6となった状態での軸方向外半部)の形状に見合う、下側凹部34を形成している。一方、上記マンドレル29の上部外周面には、上記外輪6の内周面の1対の外輪軌道11a、11b(図4〜5参照)のうちの一方(図示の例では軸方向外側)の外輪軌道11aを形成する為の、面押し部35を設けている。   A thick cylindrical lower mold 32 is fitted and fixed inside the upper portion of the lower holding cylinder 26. The upper part of the lower punch 30 is inserted into the center hole 33 of the lower mold 32 in a dense and axially displaceable state (up and down). Further, on the upper surface of the lower die 32, in the peripheral portion of the center hole 33, one half of the coupling flange 12 (see FIGS. 4 to 5) to be formed on the outer peripheral surface of the outer ring 6 (the state where the outer ring 6 is formed) The lower concave portion 34 corresponding to the shape of the outer half portion in the axial direction) is formed. On the other hand, on the upper outer peripheral surface of the mandrel 29, the outer ring of one of the pair of outer ring raceways 11a and 11b (see FIGS. 4 to 5) on the inner peripheral surface of the outer ring 6 (in the illustrated example, the outer side in the axial direction). A surface pressing portion 35 for forming the track 11a is provided.

一方、上記下板25の上方に上板36を、この下板25と平行に設けている。この上板36は、プレス加工機のラム(図示省略)の下面に取り付け固定するもので、この上板36の下面に上型37を、若干の昇降を可能に支持している。即ち、この上板36の下面に固定した上側保持筒38の内側に上記上型37を、所定量の昇降を可能に保持している。そして、この上型37の上面と上記上板36の下面との間に、圧縮コイルばね、ゴムの如きエラストマー等の弾性部材39を挟持して、上記上型37に、下方に向かう弾力を付与している。尚、この上型37に下方に向く弾力を付与する為には、上記弾性部材39による他、ガス圧或いは油圧を利用しても良い。   On the other hand, an upper plate 36 is provided above the lower plate 25 in parallel with the lower plate 25. The upper plate 36 is attached and fixed to the lower surface of a ram (not shown) of the press machine, and an upper die 37 is supported on the lower surface of the upper plate 36 so as to be able to move up and down slightly. That is, the upper die 37 is held inside the upper holding cylinder 38 fixed to the lower surface of the upper plate 36 so as to be able to move up and down by a predetermined amount. Then, an elastic member 39 such as a compression coil spring or an elastomer such as rubber is sandwiched between the upper surface of the upper die 37 and the lower surface of the upper plate 36 to give the upper die 37 elasticity downward. is doing. In addition, in order to give downward elasticity to the upper die 37, gas pressure or hydraulic pressure may be used in addition to the elastic member 39.

上記上型37には、中間素材40の上半部(上記外輪6となった状態での軸方向内半部)を密に内嵌できる中心孔41を形成している。又、上記上型37の下面のうち、この中心孔41の周囲部分で、上記下側凹部34に整合する部分には、上記結合フランジ12の他半部(上記外輪6となった状態での軸方向内半部)の形状に見合う、上側凹部42を形成している。更に、上記上型37の内側に、上側パンチ43を固定している。図示の例では、この上側パンチ43は、それぞれが円筒状の外径側パンチ44と内径側パンチ45とから成る。そして、この上側パンチ43の先端面(下端面)により上記中間素材40を下方に押圧する様にしている。尚、この上側パンチ43の先端面は、上記外径側、内径側両パンチ44、45の先端面位置をずらせる事により段付形状として、上記上側パンチ43の先端面により上記中間素材40を下方に押圧すると同時に、この中間素材40の上端部を段付形状に塑性加工する様にしている。   The upper die 37 is formed with a center hole 41 into which the upper half of the intermediate material 40 (the inner half in the axial direction in the state of the outer ring 6) can be closely fitted. Further, in the lower surface of the upper die 37, the portion around the center hole 41 and the portion that aligns with the lower concave portion 34 is provided in the other half of the coupling flange 12 (in the state of the outer ring 6). An upper concave portion 42 corresponding to the shape of the inner half portion in the axial direction is formed. Further, an upper punch 43 is fixed inside the upper die 37. In the illustrated example, the upper punch 43 includes a cylindrical outer diameter side punch 44 and an inner diameter side punch 45. The intermediate material 40 is pressed downward by the front end surface (lower end surface) of the upper punch 43. The tip surface of the upper punch 43 has a stepped shape by shifting the positions of the tip surfaces of the outer and inner diameter side punches 44 and 45, and the intermediate material 40 is formed by the tip surface of the upper punch 43. At the same time as pressing downward, the upper end portion of the intermediate material 40 is plastically processed into a stepped shape.

次に、上述の様な構成を有する製造装置により、上記中間素材40を、より上記外輪6の形状に近い、第二中間素材46に加工する工程に就いて説明する。先ず、上記中間素材40を、図6の右半部に示す様に、上記下型32と上記上型37との間に装着する。上記中間素材40は、予め外周面中間部に段付部47を、温間鍛造加工或いは冷間鍛造加工により形成したもので、下半部(上記外輪6となった状態での軸方向外半部)の外径が上半部(上記外輪6となった状態での軸方向内半部)の外径よりも小さくなっている。内径は、全長に亙り同じである。この様な中間素材40を、上記下型32の上半部内周面と前記マンドレル29の上部外周面との間に装着する。この装着作業は、プレス加工機のラムと共に上記上型37及び上記上側パンチ43を上昇させた状態で行なう。   Next, the process of processing the intermediate material 40 into the second intermediate material 46 closer to the shape of the outer ring 6 by the manufacturing apparatus having the above-described configuration will be described. First, the intermediate material 40 is mounted between the lower mold 32 and the upper mold 37 as shown in the right half of FIG. The intermediate material 40 is formed by previously forming a stepped portion 47 in the intermediate portion of the outer peripheral surface by a warm forging process or a cold forging process, and a lower half portion (an outer half in the axial direction in the state where the outer ring 6 is formed). The outer diameter of the upper part is smaller than the outer diameter of the upper half (the inner half in the axial direction when the outer ring 6 is formed). The inner diameter is the same over the entire length. Such an intermediate material 40 is mounted between the upper half inner peripheral surface of the lower mold 32 and the upper outer peripheral surface of the mandrel 29. This mounting operation is performed with the upper die 37 and the upper punch 43 raised together with the ram of the press machine.

次いで、それ迄上昇していた上記ラムを下降させ、先ず、図6の右半部に示す様に、上記下型32の上面外径寄り部分と、上記上型37の下面外径寄り部分とを突き合わせる。次いで、上記ラムを更に下降させ、上記上側パンチ43により上記中間素材40を、上記下側パンチ30に向け、強く押圧する。この際、前記弾性部材39が弾性的に圧縮される。この状態では、上記下型32の上面外径寄り部分と上記上型37の下面外径寄り部分とが密に突き合わされた状態のまま、上記上側パンチ43のみが下降する。この結果、上記中間素材40の下半部が、塑性変形しつつ、上記下型32の中間部下半寄り部分の内周面と、上記マンドレル29の外周面のうちで前記面押し部35よりも下側部分との間の、円筒状空間48内に押し込まれる。そして、上記中間素材40の下半部が、この円筒状空間48に倣った形状に塑性加工される。この状態で、一方(軸方向外側)の外輪軌道11aが形成される。   Next, the ram that has been raised is lowered. First, as shown in the right half of FIG. 6, a portion near the upper surface outer diameter of the lower die 32 and a portion near the lower surface outer diameter of the upper die 37. Match. Next, the ram is further lowered, and the intermediate material 40 is strongly pressed toward the lower punch 30 by the upper punch 43. At this time, the elastic member 39 is elastically compressed. In this state, only the upper punch 43 is lowered while the portion near the upper surface outer diameter of the lower die 32 and the portion near the lower surface outer diameter of the upper die 37 are closely abutted. As a result, the lower half portion of the intermediate material 40 is plastically deformed, and the inner peripheral surface of the lower half portion of the lower mold 32 and the outer peripheral surface of the mandrel 29 are more than the surface pressing portion 35. It is pushed into the cylindrical space 48 between the lower part. Then, the lower half of the intermediate material 40 is plastic processed into a shape following the cylindrical space 48. In this state, one (axially outer) outer ring raceway 11a is formed.

上記上側パンチ43の下降は、上記中間素材40の下半部を上記円筒状空間48に完全に押し込んだ後迄継続する。この結果、この中間素材40の一部が、前記下側凹部34と前記上側凹部42とにより構成される放射状空間49内に流れ込み(フローし)、前記結合フランジ12が形成される。この状態で、上記中間素材40が、より上記外輪6の形状に近い、前記第二中間素材46に加工される。その後、上記ラムを再び上昇させて、上記結合フランジ12を形成された上記第二中間素材46を取り出す。この取り出し作業は、前記下側パンチ30を上昇させる事で行なう。そして、取り出した上記第二中間素材46に、内周面に他方(軸方向内側)の外輪軌道11bを形成したり、内周面の必要個所を焼き入れ硬化する等の必要な後加工(必要とする切削加工、熱処理加工、研削加工等の後加工)を施してから、他の部材と組み合わせ、前述の図4〜5に示す様な、車輪支持用転がり軸受ユニットとする。   The lowering of the upper punch 43 continues until the lower half of the intermediate material 40 is completely pushed into the cylindrical space 48. As a result, a part of the intermediate material 40 flows (flows) into the radial space 49 constituted by the lower recess 34 and the upper recess 42, and the coupling flange 12 is formed. In this state, the intermediate material 40 is processed into the second intermediate material 46 that is closer to the shape of the outer ring 6. Thereafter, the ram is raised again, and the second intermediate material 46 formed with the coupling flange 12 is taken out. This removal operation is performed by raising the lower punch 30. Then, necessary post-processing (necessary) such as forming the other (axially inner) outer ring raceway 11b on the inner peripheral surface or quenching and hardening a necessary portion of the inner peripheral surface on the taken out second intermediate material 46. The post-processing such as cutting processing, heat treatment processing, grinding processing, etc. is performed, and then combined with other members to form a wheel bearing rolling bearing unit as shown in FIGS.

上述の様にして、上記結合フランジ12を有する上記第二中間素材46を造れば、上記外輪6を、必要とする精度を確保しつつ、低コストで造れる。即ち、この第二中間素材46の外形を、完成状態での外輪6の外形に近く(精度良く)できる為、後工程の切削工程での取り代を低減し、切削工程に要する時間の短縮と材料の歩留り向上とを図れる。上記中間素材40から上記第二中間素材46への加工は、冷間鍛造の1種である側方押し出し加工により行なうが、比較的低荷重で行なう事ができて、設備投資並びに運転経費を安く抑えられる。そして、得られた外輪6の強度を十分に大きくできる。
但し、より良質の外輪6を得る為には、側方押し出し工程に改良を加える必要がある事が、本発明者等の研究により分かった。この点に就いて、以下に説明する。
If the second intermediate material 46 having the coupling flange 12 is manufactured as described above, the outer ring 6 can be manufactured at a low cost while ensuring the required accuracy. That is, since the outer shape of the second intermediate material 46 can be close to the outer ring 6 in the completed state (with high accuracy), the machining allowance in the subsequent cutting process is reduced, and the time required for the cutting process is shortened. The yield of the material can be improved. The processing from the intermediate material 40 to the second intermediate material 46 is performed by side extrusion, which is a kind of cold forging, but can be performed with a relatively low load, and the equipment investment and operation cost are reduced. It can be suppressed. And the intensity | strength of the obtained outer ring | wheel 6 can fully be enlarged.
However, in order to obtain a better quality outer ring 6, it has been found by the present inventors that it is necessary to improve the side extrusion process. This point will be described below.

図6に示す様な側方押し出し加工により、突出部を備えた筒状部材を加工した場合、この筒状部材の内周面の一部でこの突出部の内径側に存在する部分に凹部が形成される場合がある。例えば、上記中間素材40から、上記第二中間素材46を加工した場合、図7に示す様に、この第二中間素材46の内周面の一部で結合フランジ12の内径側に整合する部分に、凹部50、50が形成される場合がある。この様な凹部50、50は、常に形成されるとは限らないが、素材の肉厚や、上記結合フランジ12を加工すべき放射状空間49への金属材料の流動のし易さ等、加工時に於ける各種条件のバランスによって、次の様な機構により形成される。   When a cylindrical member provided with a protruding portion is processed by side extrusion as shown in FIG. 6, a recess is formed in a portion of the inner peripheral surface of the cylindrical member that is present on the inner diameter side of the protruding portion. May be formed. For example, when the second intermediate material 46 is processed from the intermediate material 40, a part of the inner peripheral surface of the second intermediate material 46 aligned with the inner diameter side of the coupling flange 12 as shown in FIG. In addition, the recesses 50 and 50 may be formed. Such recesses 50, 50 are not always formed, but during processing, such as the thickness of the material and the ease of flow of the metal material into the radial space 49 where the coupling flange 12 is to be processed. It is formed by the following mechanism according to the balance of various conditions.

即ち、上記側方押し出し加工により上記結合フランジ12を形成する際には、図8に矢印で示す様に、上記第二中間素材46の本体部分(円筒状部分)から、放射方向外側に延出する上記結合フランジ12に向けて金属材料が流動する。この流動に伴って、この結合フランジ12の内径側に存在する、上記本体部分を構成すべき金属材料までもが径方向外方に引っ張られる。その結果、上記第二中間素材46の内周面の一部で結合フランジ12の内径側に整合する部分に、上記凹部50、50が生じてしまう。   That is, when the connecting flange 12 is formed by the side extrusion, as shown by an arrow in FIG. 8, it extends radially outward from the main body portion (cylindrical portion) of the second intermediate material 46. The metal material flows toward the connecting flange 12. Along with this flow, the metal material that is to be included in the main body portion and exists on the inner diameter side of the coupling flange 12 is also pulled outward in the radial direction. As a result, the concave portions 50 and 50 are formed in a portion of the inner peripheral surface of the second intermediate material 46 that is aligned with the inner diameter side of the coupling flange 12.

この様な凹部50、50を放置した場合、応力集中により、得られた外輪6の強度確保が難しくなるので、これを除去する必要がある。ところが、上記凹部50、50を除去する為には、その分だけ、後工程に於ける切削加工での取り代を多くする必要があり、切削工程に要する時間の増大と材料の歩留り低下とにより、上記外輪6の製造コストを上昇させてしまう。しかも、上記凹部50、50は、上記第二中間素材46の内周面に、全周に亙り不均一に形成される為、この凹部50、50を切削加工により除去する際の切削状況は、断続的になり、バイト等の切削工具の寿命確保が難しい。従って、この面からも、上記外輪6の製造コストを高くする。   If such concave portions 50 are left unattended, it is difficult to ensure the strength of the obtained outer ring 6 due to stress concentration, so it is necessary to remove it. However, in order to remove the recesses 50 and 50, it is necessary to increase the machining allowance in the cutting process in the subsequent process, and due to the increase in time required for the cutting process and the decrease in the yield of the material. The manufacturing cost of the outer ring 6 will be increased. And since the said recessed parts 50 and 50 are formed in the inner peripheral surface of the said 2nd intermediate raw material 46 nonuniformly over the perimeter, the cutting condition at the time of removing this recessed part 50 and 50 by cutting is as follows. It becomes intermittent and it is difficult to ensure the life of cutting tools such as tools. Therefore, also from this aspect, the manufacturing cost of the outer ring 6 is increased.

単に、上記凹部50、50が生じる事を防止するだけであれば、前記中間素材40の径方向に関する肉厚を大きくすれば良い。肉厚を大きくすれば、上記結合フランジ12部分への材料供給が良好に行なわれる事に加えて、前記放射状空間49と上記中間素材40の内周面との距離が長くなる為、上記凹部50、50が生じにくくなる。但し、肉厚を大きくすると、前記側方押し出し加工時にラムを下降させる為に要する力(加工荷重)が大きくなる。しかも、上記外輪6の重量が徒に増大する事を防止する為には、後工程で行なう切削加工時の取り代が大きくなる等により、製造コストが高くなってしまう。   The thickness of the intermediate material 40 in the radial direction may be increased if the above-described recesses 50 are merely prevented. If the wall thickness is increased, the material is supplied well to the connecting flange 12 portion, and the distance between the radial space 49 and the inner peripheral surface of the intermediate material 40 is increased. , 50 is less likely to occur. However, when the wall thickness is increased, the force (working load) required for lowering the ram during the side extrusion processing increases. In addition, in order to prevent the weight of the outer ring 6 from increasing unnecessarily, the manufacturing cost increases due to an increase in machining allowance at the time of cutting performed in a subsequent process.

尚、特許文献1〜3には、位置決め筒部と、取付フランジと、中間部と、小径段部とを備えたハブの構造に関する発明が記載されている。但し、上記特許文献1〜3に記載された発明は、何れも、位置決め筒部や取付フランジを容易に加工若しくは設置できる様にする為の構造に関するものであり、外輪の外周面に結合フランジを、冷間鍛造により精度良く加工できる様にする技術を示唆するものではない。   Patent Documents 1 to 3 describe inventions related to the structure of a hub including a positioning cylinder portion, a mounting flange, an intermediate portion, and a small diameter step portion. However, all of the inventions described in the above-mentioned Patent Documents 1 to 3 relate to a structure for enabling easy processing or installation of the positioning cylinder part and the mounting flange, and a coupling flange is provided on the outer peripheral surface of the outer ring. However, this does not suggest a technique for enabling accurate processing by cold forging.

特開2003−25803号公報JP 2003-25803 A 特開2003−291604号公報JP 2003-291604 A 特開2004−74815号公報JP 2004-74815 A

本発明は、上述の様な事情に鑑みて、例えば外周面の一部で円周方向複数箇所から径方向外方に向け、放射方向に突出した状態で設けられた複数の突出部から成る結合フランジを備えた外輪を、冷間鍛造により精度良く、しかも内周面に凹部等が形成されずに、安定して加工できる製造方法を実現すべく発明したものである。 In view of the circumstances as described above, the present invention is, for example, a combination of a plurality of projecting portions provided in a state of projecting in a radial direction from a plurality of locations in the circumferential direction toward a radially outward direction at a part of the outer peripheral surface. The present invention has been invented to realize a manufacturing method capable of processing an outer ring provided with a flange with high accuracy by cold forging and without forming recesses or the like on the inner peripheral surface.

本発明の突出部を備えた筒状部材の製造方法は、図6により先に説明した、先発明に係る製造方法と同様に、筒状で金属製の素材の内側にマンドレルを挿入して、この素材が内径側に変形するのを抑えると共に、この素材の周囲に配置された、軸方向に2分割される1対の外径側金型の内周面によりこの素材の外周面の一部を抑えた状態で、この素材を軸方向に圧縮する。そして、この素材の外周面の残部で上記両外径側金型の内周面により抑えられていない部分を径方向外方に塑性変形させる側方押出加工により、外周面の円周方向複数箇所から径方向外方に向け、放射方向に突出した複数の突出部を形成する。 The manufacturing method of the cylindrical member provided with the protruding portion of the present invention is similar to the manufacturing method according to the previous invention described above with reference to FIG. 6, and a mandrel is inserted inside the cylindrical and metal material, A part of the outer peripheral surface of the material is suppressed by the inner peripheral surface of a pair of outer diameter side molds arranged in the axial direction and arranged around the material while suppressing the deformation of the material toward the inner diameter side. This material is compressed in the axial direction in a state where the pressure is suppressed. And by the side extrusion which plastically deforms the part which is not restrained by the inner peripheral surface of the both outer diameter side molds in the remaining part of the outer peripheral surface of this material, a plurality of locations in the circumferential direction of the outer peripheral surface radially outward from, to form a plurality of protrusions projecting radially.

特に、本発明の突出部を備えた筒状部材の製造方法では、上記マンドレルとして、軸方向に2分割された1対のマンドレル素子を、上記突出部となる部分の内径側部分で突き合わせて成るものを使用する。そして、これら両マンドレル素子を互いに近づく方向に弾性的に押圧しつつ、上記素材を軸方向に圧縮する事により、上記突出部を形成すると同時に、この素材の一部を上記両マンドレル素子の突き合わせ部の外径寄り部分に存在する環状隙間若しくは環状溝に進入させ、この突き合わせ部に対応する部分に径方向内方に突出するバリ状余肉部を形成して中間素材とする。その後、上記両マンドレル素子を離隔させた状態でこの中間素材をこれら両マンドレル素子同士の間から抜き出してから、上記バリ状余肉部を除去する。 In particular, in the method for manufacturing a cylindrical member having a protruding portion according to the present invention, as the mandrel, a pair of mandrel elements divided into two in the axial direction are abutted on the inner diameter side portion of the portion that becomes the protruding portion. Use things. And while pressing both the mandrel elements elastically in the direction approaching each other, the material is compressed in the axial direction to form the protruding portion, and at the same time, a part of the material is abutted portion of the both mandrel elements. It is made to enter into an annular gap or an annular groove existing in a portion near the outer diameter, and a burr-like surplus portion protruding inward in the radial direction is formed in a portion corresponding to the abutting portion as an intermediate material. Thereafter, the intermediate material is extracted from between the two mandrel elements in a state where the two mandrel elements are separated from each other, and then the burr-like surplus portion is removed.

上述の本発明の製造方法の発明を実施する場合に、例えば請求項2に記載した発明の様に、突出部を備えた筒状部材を、車輪支持用転がり軸受ユニットを構成する為の外輪とする。そして、外周面に形成された突出部を、この外輪を懸架装置に結合固定する為のフランジ部とする。
この様な請求項2に記載した発明を実施する場合に、例えば請求項3に記載した発明の様に、外輪を、この外輪の内径側に複列に配置された転動体に背面組み合わせ型の接触角を付与する為の複列の外輪軌道を内周面に有するものとする。そして、少なくとも一方のマンドレル素子の外周面により、フランジ部の加工と同時に、上記両外輪軌道のうちの一方の外輪軌道を形成する。
When carrying out the invention of the manufacturing method of the present invention described above, for example, as in the invention described in claim 2, a cylindrical member provided with a projecting portion is used as an outer ring for constituting a wheel bearing rolling bearing unit. To do. And the protrusion part formed in the outer peripheral surface is taken as the flange part for couple | bonding and fixing this outer ring | wheel to a suspension apparatus.
When the invention described in claim 2 is carried out, as in the invention described in claim 3, for example, the outer ring is a rear combined type with rolling elements arranged in double rows on the inner diameter side of the outer ring. A double row outer ring raceway for providing a contact angle is provided on the inner peripheral surface. At least one of the outer ring raceways is formed simultaneously with the processing of the flange portion by the outer peripheral surface of at least one mandrel element.

上述の様に構成する本発明の突出部を備えた筒状部材の製造方法によれば、例えば外周面の一部で円周方向複数箇所から径方向外方に向け、放射方向に突出した状態で設けられた複数の突出部から成る結合フランジを備えた外輪を、冷間鍛造により精度良く、しかも内周面に凹部等が形成されない様にしつつ、安定して加工できる。即ち、本発明の製造方法は、前述の図6に示した先発明の製造方法の場合と同様の理由により、車輪支持用転がり軸受ユニットを構成する外輪の如き、突出部を備えた筒状部材を、必要とする精度を確保しつつ、低コストで造れる。 According to the manufacturing method of the cylindrical member having the protruding portion of the present invention configured as described above, for example , a state in which a part of the outer peripheral surface protrudes radially outward from a plurality of locations in the circumferential direction. The outer ring provided with the coupling flange composed of a plurality of projecting portions provided in (5) can be processed stably with high accuracy by cold forging while preventing a recess or the like from being formed on the inner peripheral surface. That is, the manufacturing method of the present invention is a cylindrical member provided with a projecting portion such as an outer ring constituting a wheel bearing rolling bearing unit for the same reason as in the manufacturing method of the prior invention shown in FIG. Can be manufactured at low cost while ensuring the required accuracy.

更に、本発明の製造方法によれば、結合フランジの如き突出部を形成すべき部分の内径側に、1対のマンドレル素子の先端面同士の突き合わせ部に対応して、隙間(環状隙間若しくは環状溝)が存在する。そして、上記突出部を形成する為の側方押し出し加工の際に、上記筒状部材を構成する金属材料の一部が上記隙間に進入し、径方向内方に突出するバリ状余肉部を形成する。要するに、この隙間の存在により、上記金属材料の一部で軸方向位置が上記突出部に対応する部分に、径方向内方に向かう流れが惹起される。即ち、側方押し出し加工時に於ける、上記突出部に対応する部分での金属材料の流れを見た場合に、上記先発明では、外周面から内周面に至る迄(厚さ全体に亙り)径方向外方に向かう流れが支配的であった。これに対して本発明の場合には、少なくとも内周面近傍部分で、径方向内方に向かう流れが支配的となる。 Furthermore, according to the manufacturing method of the present invention, a gap (an annular gap or an annular gap) is formed on the inner diameter side of a portion where a protruding portion such as a coupling flange is to be formed, corresponding to the abutting portion between the tip surfaces of a pair of mandrel elements. Groove) . Then, during the side extrusion process for forming the protruding portion, a part of the metal material constituting the cylindrical member enters the gap, and a burr-like surplus portion protruding inward in the radial direction is formed. Form. In short, the presence of this gap causes a flow inward in the radial direction in a part of the metal material whose axial position corresponds to the protrusion. That is, when the flow of the metal material at the portion corresponding to the protruding portion at the time of side extrusion processing is seen, in the above invention, from the outer peripheral surface to the inner peripheral surface (over the entire thickness). The radially outward flow was dominant. On the other hand, in the case of the present invention, the flow inward in the radial direction is dominant at least in the vicinity of the inner peripheral surface.

この結果、中間素材の内周面のうちで上記突出部の内径側に対応する部分に、凹部が生じる事がない。上記バリ状余肉部は、打ち抜き加工、旋削加工等の後加工により除去する必要があるが、このバリ状余肉部は、薄肉で容積が小さく、しかもほぼ全周に亙り連続した形状である為、除去に要する手間は簡単で済み、しかもスクラップとなる部分の容積も極く僅かで済む(材料の歩留り低下は極く僅かで済む)。又、上記バリ状余肉部を、1対のマンドレル素子の突き合わせ部に形成する為、上記側方押し出し加工により上記突出部及びバリ状余肉部を形成した上記中間素材は、上記両マンドレル素子を離隔させる事により、これら両マンドレル素子の間から抜き出せる。これに対して、上記凹部が生じるのを防止する事のみを考慮すれば、一体型のマンドレルの外周面で上記突出部の内径側に対応する部分に凹溝を形成すれば良い。但し、この場合には、側方押し出し加工に伴って内径側に流動した金属材料と上記凹溝とが噛み合って、上記突出部を形成した中間素材を取り出せなくなる。   As a result, no concave portion is generated in a portion corresponding to the inner diameter side of the protruding portion in the inner peripheral surface of the intermediate material. The burr-like surplus part needs to be removed by post-processing such as punching and turning, but this burr-like surplus part is thin and small in volume, and has a shape that is continuous over the entire circumference. Therefore, the labor required for the removal is simple, and the volume of the portion to be scrapped is very small (the material yield reduction is very small). Moreover, in order to form the said burr-like surplus part in the butt | matching part of a pair of mandrel elements, the said intermediate material which formed the said protrusion part and the burr-like surplus part by the said side extrusion process is the said both mandrel elements. Can be extracted from between these two mandrel elements. On the other hand, if only the prevention of the formation of the concave portion is taken into consideration, a concave groove may be formed in a portion corresponding to the inner diameter side of the protruding portion on the outer peripheral surface of the integral mandrel. However, in this case, the metal material that has flowed to the inner diameter side with the side extrusion process meshes with the concave groove, so that the intermediate material having the protruding portion cannot be taken out.

図1〜3は、本発明の実施の形態の1例を示している。先ず、図1は、円筒状の素材51を、外輪6に近い形状の第三中間素材52に加工する為の全工程を示している。図1の(A)に示した素材51は、先ず、冷間鍛造の1種である前方押し出し加工により、図1の(B)に示す様な、外周面を段付形状とした中間素材40(特許請求の範囲に記載した素材)に加工する。この前方押し出し加工は、上記素材51を円柱状のマンドレルに外嵌した状態でこの素材51を、内周面を段付形状とした外型内に押し込む事により行なう。前方押し出し加工に就いては、前述の特願2004−298585号に開示されており、本発明の要旨とも関係しないので、図示並びに詳しい説明は省略する。 1 to 3 show an example of an embodiment of the present invention . First, FIG. 1 shows all steps for processing a cylindrical material 51 into a third intermediate material 52 having a shape close to the outer ring 6. The material 51 shown in FIG. 1A is first an intermediate material 40 having a stepped outer peripheral surface as shown in FIG. 1B by forward extrusion, which is a type of cold forging. Processed into (the material described in the claims). This forward extrusion process is performed by pushing the material 51 into an outer mold having a stepped inner peripheral surface in a state where the material 51 is fitted on a cylindrical mandrel. The forward extrusion process is disclosed in the above-mentioned Japanese Patent Application No. 2004-298585, and is not related to the gist of the present invention.

上記中間素材40は、本発明の特徴である側方押し出し加工により塑性変形させて、図1の(C)に示す様な第二中間素材46a(特許請求の範囲に記載した中間素材)とする。この側方押し出し加工に就いては、基本的には、前述の図6で示した先発明の場合と同様にして行なうが、この先発明と異なる点に就いては、図2により、後で詳しく説明する。更に、本発明を実施する事により得られる、上記第二中間素材46aの内周面には、上記先発明を実施する事により得られる第二中間素材46(図6の左半部)とは異なり、内周面の中間部で、突出部である結合フランジ12の内径側部分に、内向鍔状のバリ状余肉部53が存在する。そこで、プレスによる打ち抜き加工、或いは旋削加工等により、上記バリ状余肉部53を除去し、図1の(D)に示す様な第三中間素材52とする。この第三中間素材52は、内周面に他方(軸方向内側)の外輪軌道11b(図4〜5参照)を形成したり、内周面の必要個所を焼き入れ硬化する等の必要な後加工(必要とする切削加工、熱処理加工、研削加工等の後加工)を施してから、他の部材と組み合わせ、前述の図4〜5に示す様な、車輪支持用転がり軸受ユニットとする。   The intermediate material 40 is plastically deformed by side extrusion, which is a feature of the present invention, to form a second intermediate material 46a (intermediate material described in claims) as shown in FIG. . The side extrusion is basically performed in the same manner as in the case of the prior invention shown in FIG. 6 described above, but the points different from the prior invention will be described in detail later with reference to FIG. explain. Further, on the inner peripheral surface of the second intermediate material 46a obtained by carrying out the present invention, the second intermediate material 46 (left half part in FIG. 6) obtained by carrying out the above invention is defined. In contrast, an inward ridge-shaped burr-like surplus portion 53 exists at the inner diameter side portion of the coupling flange 12 that is a projecting portion at an intermediate portion of the inner peripheral surface. Accordingly, the burr-like surplus portion 53 is removed by punching or turning with a press to obtain a third intermediate material 52 as shown in FIG. This third intermediate material 52 is formed after the other (axially inner) outer ring raceway 11b (see FIGS. 4 to 5) is formed on the inner peripheral surface, and necessary portions of the inner peripheral surface are quenched and hardened. After processing (post-processing such as necessary cutting, heat treatment, and grinding), it is combined with other members to form a rolling bearing unit for supporting a wheel as shown in FIGS.

次いで、本発明の要点である、上記中間素材40を塑性変形させて上記第二中間素材46aとする、側方押し出し加工に就いて、図2に示した製造装置を参照しつつ説明する。この図2に示した製造装置は、基本的には、前述の図6に示した、先発明に係る製造装置と同様であり、右半部は加工開始直前の状態を、左半部は加工終了直後の状態を、それぞれ示している。就いては、上記先発明に係る製造装置と構成が同じ部分には同一符号を付して重複する説明を省略し、以下、この先発明に係る製造装置と構成が異なる部分を中心に説明する。本発明の製造方法に用いる製造装置の場合には、マンドレル29aを、上下方向に2分割された、上側マンドレル素子54と下側マンドレル素子55とにより構成している。これら上側、下側両マンドレル素子54、55は、突き合わせ端部同士が互いに同じ外径を有する円柱状で、互いに同心に配置されている。 Next, a side extrusion process in which the intermediate material 40 is plastically deformed to form the second intermediate material 46a, which is the main point of the present invention, will be described with reference to the manufacturing apparatus shown in FIG. The manufacturing apparatus shown in FIG. 2 is basically the same as the manufacturing apparatus according to the previous invention shown in FIG. 6 described above, with the right half part immediately before the start of processing and the left half part processed. Each state immediately after the end is shown. Therefore, the same reference numerals are given to the same parts as those in the manufacturing apparatus according to the above-described invention, and redundant description will be omitted. Hereinafter, the description will focus on the parts that are different from the manufacturing apparatus according to the above-described invention. In the case of a manufacturing apparatus used in the manufacturing method of the present invention, the mandrel 29a is constituted by an upper mandrel element 54 and a lower mandrel element 55 which are divided into two in the vertical direction. Both the upper and lower mandrel elements 54 and 55 are in a cylindrical shape in which the butted ends have the same outer diameter, and are arranged concentrically with each other.

このうちの下側マンドレル素子55は下板25の中央部上面に、下型32と同心に固定されている。この下側マンドレル素子55を下板25の上面に固定する点に関しては、上記先発明に係る製造装置が、マンドレル29を下板25の上面に固定するのと同じである。これに対して上記上側マンドレル素子54は上板36の下方に、この上板36に対する若干の昇降を可能に、上型37と同心に、支持し(吊り下げ)ている。即ち、上記上側マンドレル素子54の上部を、上記上板36の下面に固定された上側パンチ43の内側に、所定量の昇降を可能に内嵌保持している。更に、上記上側マンドレル素子54の上端面と上記上板36の下面中央部との間に第二弾性部材56を設けて、この上側マンドレル素子54に対し、下方に向く方向の弾力を付与している。尚、上記第二弾性部材56に就いても、上記上型37の上面と上記上板36の下面との間に設ける弾性部材39と同様に、圧縮コイルばね、ゴムの如きエラストマーを使用できる他、ガス圧或いは油圧を利用して、上記上側マンドレル素子54に、下方に向く弾力を付与しても良い。   Of these, the lower mandrel element 55 is fixed to the upper surface of the central portion of the lower plate 25 concentrically with the lower mold 32. The lower mandrel element 55 is fixed to the upper surface of the lower plate 25 in the same manner as the manufacturing apparatus according to the above invention fixes the mandrel 29 to the upper surface of the lower plate 25. On the other hand, the upper mandrel element 54 is supported (suspended) below the upper plate 36 and concentrically with the upper die 37 so that the upper mandrel element 54 can be slightly lifted with respect to the upper plate 36. That is, the upper part of the upper mandrel element 54 is fitted and held inside the upper punch 43 fixed to the lower surface of the upper plate 36 so as to be able to move up and down by a predetermined amount. Further, a second elastic member 56 is provided between the upper end surface of the upper mandrel element 54 and the center of the lower surface of the upper plate 36, and an elastic force in a downward direction is applied to the upper mandrel element 54. Yes. The second elastic member 56 can be made of an elastomer such as a compression coil spring or rubber, similarly to the elastic member 39 provided between the upper surface of the upper die 37 and the lower surface of the upper plate 36. Alternatively, a downward elastic force may be applied to the upper mandrel element 54 using gas pressure or hydraulic pressure.

更に、上記上側マンドレル素子54の下面中央部と、上記下側マンドレル素子55の上面中央部とは、それぞれの面の外径寄り部分に比べて、少しだけ(例えば0.2〜1mm程度)軸方向に突出させている。従って、上記上側マンドレル素子54の下面と上記下側マンドレル素子55の上面とを突き合わせた状態では、これら両面の外径寄り部分同士の間に、薄い(軸方向厚さが0.4〜2mm程度の)環状隙間57が、全周に亙って形成される。尚、この環状隙間57の、径方向に関する幅寸法は特に問わない。1〜2mm程度あれば十分である。又、上記上側マンドレル素子54の下面と上記下側マンドレル素子55の上面との外周縁部に面取りを形成して、これら両面の面取りが合わさって形成される環状溝を、上記環状隙間57の代わりとする事もできる。   Further, the lower surface center portion of the upper mandrel element 54 and the upper surface center portion of the lower mandrel element 55 are slightly (for example, about 0.2 to 1 mm) in axis compared to the portions near the outer diameter of the respective surfaces. It protrudes in the direction. Therefore, in a state where the lower surface of the upper mandrel element 54 and the upper surface of the lower mandrel element 55 are in contact with each other, the gap between the outer diameter portions of both surfaces is thin (the axial thickness is about 0.4 to 2 mm). A) annular gap 57 is formed over the entire circumference. The width dimension of the annular gap 57 in the radial direction is not particularly limited. About 1 to 2 mm is sufficient. Further, a chamfer is formed on the outer peripheral edge of the lower surface of the upper mandrel element 54 and the upper surface of the lower mandrel element 55, and an annular groove formed by combining these two chamfers is formed in place of the annular gap 57. It can also be.

上述の様に構成する本例の製造装置により、前記中間素材40を塑性変形させて前記第二中間素材46aとする、側方押し出し加工の際には、先ず、上記中間素材40を、図2の右半部に示す様に、下型32と上型37との間に装着する。この装着作業は、プレス加工機のラムと共に上型37及び上側パンチ43を上昇させた状態で行なう。
次いで、それ迄上昇していた上記ラムを下降させ、先ず、図2の右半部に示す様に、上記下型32の上面外径寄り部分と、上記上型37の下面外径寄り部分とを突き合わせると共に、上記上側マンドレル素子54の下面と上記下側マンドレル素子55の上面とを突き合わせる。これら各面同士の突き合わせは、同時であっても、多少前後しても良い。
In the side extrusion process in which the intermediate material 40 is plastically deformed to form the second intermediate material 46a by the manufacturing apparatus of the present example configured as described above, first, the intermediate material 40 is formed as shown in FIG. As shown in the right half of the figure, it is mounted between the lower mold 32 and the upper mold 37. This mounting operation is performed with the upper die 37 and the upper punch 43 raised together with the ram of the press machine.
Next, the ram that has been raised is lowered, and first, as shown in the right half of FIG. 2, a portion near the upper surface outer diameter of the lower die 32 and a portion near the lower surface outer diameter of the upper die 37 And the lower surface of the upper mandrel element 54 and the upper surface of the lower mandrel element 55 are abutted. These faces may be matched at the same time or slightly before and after.

次いで、上記ラムを更に下降させ、上記上側パンチ43により上記中間素材40を、下側パンチ30に向け、強く押圧する。この際、前記弾性部材39及び前記第二弾性部材56が弾性的に圧縮される。この状態では、上記下型32の上面外径寄り部分と上記上型37の下面外径寄り部分とが、上記上側マンドレル素子54の下面中央部と上記下側マンドレル素子55の上面中央部とが、それぞれ密に突き合わされた状態のまま、上記上側パンチ43のみが下降する。
この結果、上記中間素材40の下半部が、塑性変形しつつ、上記下型32の中間部下半寄り部分の内周面と、上記下側マンドレル素子55の外周面のうちで前記面押し部35よりも下側部分との間の円筒状空間48内に押し込まれる。そして、上記中間素材40の下半部が、この円筒状空間48に倣った形状に塑性加工される。この状態で、一方(軸方向外側)の外輪軌道11aが形成される。
Next, the ram is further lowered, and the intermediate material 40 is strongly pressed toward the lower punch 30 by the upper punch 43. At this time, the elastic member 39 and the second elastic member 56 are elastically compressed. In this state, a portion near the upper surface outer diameter of the lower die 32 and a portion near the lower surface outer diameter of the upper die 37 are formed so that the lower surface center portion of the upper mandrel element 54 and the upper surface center portion of the lower mandrel element 55 are located. Only the upper punch 43 is lowered while being in close contact with each other.
As a result, while the lower half portion of the intermediate material 40 is plastically deformed, the surface pressing portion of the inner peripheral surface of the lower half portion of the lower mold 32 and the outer peripheral surface of the lower mandrel element 55 is compressed. It is pushed into the cylindrical space 48 between the lower part than 35. Then, the lower half of the intermediate material 40 is plastic processed into a shape following the cylindrical space 48. In this state, one (axially outer) outer ring raceway 11a is formed.

上記上側パンチ43の下降は、上記中間素材40の下半部を上記円筒状空間48に完全に押し込んだ後迄継続する。この結果、この中間素材40を構成する金属材料の一部が、前記下側凹部34と前記上側凹部42とにより構成される放射状空間49内に流れ込み(フローし)、外周面の円周方向複数箇所から径方向外方に向け、放射方向に突出した複数の突出部から成る、前記結合フランジ12が形成される。この状態で、上記中間素材40が、より上記外輪6の形状に近い、前記第二中間素材46aに加工される。
本発明を実施する場合には、上記金属材料の一部が上記放射状空間49内に流れ込むと同時に、前記環状隙間57内にも流れ込む。そして、この環状隙間57に対応して、前記バリ状余肉部53を形成する。
その後、上記ラムを再び上昇させて、上記第二中間素材46aの周囲から前記上型37を、同じく内側から上記上側マンドレル素子54を、それぞれ抜き取る。次いで、上記結合フランジ12を形成された上記第二中間素材46aを、前記下型32の内側から取り出す。この取り出し作業は、前記下側パンチ30を上昇させる事で行なう。取り出した第二中間素材46aに後加工を施して前記外輪6とする事は、前述した通りである。
The lowering of the upper punch 43 continues until the lower half of the intermediate material 40 is completely pushed into the cylindrical space 48. As a result, a part of the metal material constituting the intermediate material 40 flows (flows) into the radial space 49 formed by the lower concave portion 34 and the upper concave portion 42, and a plurality of circumferential directions of the outer peripheral surface are formed. The coupling flange 12 is formed of a plurality of projecting portions projecting radially outward from the location in the radial direction . In this state, the intermediate material 40 is processed into the second intermediate material 46a that is closer to the shape of the outer ring 6.
When carrying out the present invention, a part of the metal material flows into the radial space 49 and also into the annular gap 57. Then, the burr-like surplus portion 53 is formed corresponding to the annular gap 57.
Thereafter, the ram is raised again, and the upper die 37 is removed from the periphery of the second intermediate material 46a, and the upper mandrel element 54 is similarly removed from the inner side. Next, the second intermediate material 46 a on which the coupling flange 12 is formed is taken out from the inside of the lower mold 32. This removal operation is performed by raising the lower punch 30. As described above, the second intermediate material 46a taken out is post-processed to form the outer ring 6.

上述の様に本例の製造方法によれば、外周面に結合フランジ12を備えた外輪6を、冷間鍛造により精度良く、しかも内周面に前述の図7に示した様な凹部50、50の如き欠陥を生じさせる事なく、安定して加工できる。即ち、本例の製造方法によれば、上記結合フランジ12を形成すべき部分の内径側に、上側、下側両マンドレル素子54、55の先端面同士の突き合わせ部に対応して、上記環状隙間57が存在する。そして、上記結合フランジ12を形成する為の側方押し出し加工の際に、上記中間素材40乃至上記第二中間素材46aを構成する金属材料の一部が上記環状隙間57に進入して、径方向内方に突出する、上記バリ状余肉部53を形成する。要するに、この環状隙間57の存在により、上記金属材料の一部で軸方向位置が上記結合フランジ12に対応する部分に、図3に矢印で示す様に、径方向内方に向かう流れが惹起される。即ち、側方押し出し加工時に於ける、上記結合フランジ12に対応する部分での金属材料の流れを見た場合に、前述の図6に示した先発明では、外周面から内周面に至る迄(厚さ全体に亙り)径方向外方に向かう流れが支配的であった。これに対して本例の場合には、少なくとも内周面近傍部分で、上記環状隙間57に流れ込むべく、径方向内方に向かう流れが支配的になる。 As described above , according to the manufacturing method of this example, the outer ring 6 provided with the coupling flange 12 on the outer peripheral surface is accurately formed by cold forging, and the concave portion 50 as shown in FIG. It can be processed stably without causing 50 defects. That is, according to the manufacturing method of the present example, the annular gap is formed on the inner diameter side of the portion where the coupling flange 12 is to be formed, corresponding to the abutting portion between the front end surfaces of the upper and lower mandrel elements 54 and 55. 57 exists. During the side extrusion for forming the coupling flange 12, a part of the metal material constituting the intermediate material 40 to the second intermediate material 46a enters the annular gap 57, and the radial direction The burr-like surplus portion 53 protruding inward is formed. In short, the presence of the annular gap 57 causes a flow inward in the radial direction as shown by an arrow in FIG. 3 in a part of the metal material whose axial position corresponds to the coupling flange 12. The That is, when the flow of the metal material at the portion corresponding to the connecting flange 12 in the side extrusion process is viewed, the prior invention shown in FIG. 6 described above extends from the outer peripheral surface to the inner peripheral surface. The flow toward the outside in the radial direction was dominant (over the entire thickness). On the other hand, in the case of this example, in order to flow into the annular gap 57 at least in the vicinity of the inner peripheral surface, the flow directed inward in the radial direction becomes dominant.

この結果、上記第二中間素材46aの内周面のうちで、上記結合フランジ12の内径側に対応する部分に、前述の図7に示す様な凹部50、50が生じる事がない。上記バリ状余肉部53は、打ち抜き加工、旋削加工等の後加工により除去する必要があるが、このバリ状余肉部53は、薄肉で容積が小さく、しかもほぼ全周に亙り連続した形状である為、除去に要する手間は簡単で済み、しかもスクラップとなる部分の容積も極く僅かで済む(材料の歩留り低下は極く僅かで済む)。又、上記バリ状余肉部53を、上側、下側両マンドレル素子54、55の突き合わせ部に形成する為、上記側方押し出し加工により上記結合フランジ12及び上記バリ状余肉部53を形成した上記第二中間素材46aは、上記上側マンドレル素子54を上昇させて、上記両マンドレル素子54、55を離隔させる事により、これら両マンドレル素子54、55の間から抜き出せる。   As a result, in the inner peripheral surface of the second intermediate material 46a, the concave portions 50 and 50 as shown in FIG. 7 do not occur in the portion corresponding to the inner diameter side of the coupling flange 12. The burr-like surplus portion 53 needs to be removed by post-processing such as punching and turning, but this burr-like surplus portion 53 is thin and has a small volume, and has a continuous shape over almost the entire circumference. Therefore, the labor required for the removal is simple, and the volume of the portion to be scrapped is very small (the decrease in the yield of the material is very small). Further, in order to form the burr-like surplus portion 53 at the abutting portion of both the upper and lower mandrel elements 54, 55, the coupling flange 12 and the burr-like surplus portion 53 are formed by the side extrusion. The second intermediate material 46a can be extracted from between the mandrel elements 54, 55 by raising the upper mandrel element 54 and separating the mandrel elements 54, 55.

尚、図示の例とは異なり、上記上側マンドレル素子54の下面と上記下側マンドレル素子55の上面との外周縁部に面取りを形成して、これら両面の面取りが合わさって形成される環状溝を設けた場合でも、前記中間素材40乃至上記第二中間素材46aの内周面近傍部分に、径方向内方に向かう流れを惹起できる。この場合に、上記環状溝の容積が小さくても、金属材料がこの環状溝に流れ込むと、上記上側マンドレル素子54が前記第二弾性部材56の弾力に抗して上昇する傾向になるので、上記径方向内方に向かう流れを、上記凹部50、50が生じる事を十分に防止できる程度に惹起できる。   Unlike the illustrated example, a chamfer is formed on the outer peripheral edge of the lower surface of the upper mandrel element 54 and the upper surface of the lower mandrel element 55, and an annular groove formed by combining these two chamfers is formed. Even when it is provided, a flow inward in the radial direction can be induced in the vicinity of the inner peripheral surface of the intermediate material 40 to the second intermediate material 46a. In this case, even if the volume of the annular groove is small, if the metal material flows into the annular groove, the upper mandrel element 54 tends to rise against the elasticity of the second elastic member 56. The flow inward in the radial direction can be induced to such an extent that the concave portions 50 can be sufficiently prevented.

本発明の製造方法は、外周面の円周方向複数箇所から径方向外方に向け、放射方向に突出した複数の突出部を形成した筒状部材であれば、図示の様な車輪支持用転がり軸受ユニットを構成する外輪に限らず実施できる。
又、図示は省略するが、図2に示した構造で、上側パンチ43の下端面内径寄り分から更に下方に延出する突出部を設け、この突出部の下端面部分に、軸方向内側の外輪軌道11bを形成する為の第二の面押し部を設ければ、第二中間素材の内周面に、複列の内輪軌道、若しくはこの複列の内輪軌道に近い形状を有する部分を加工できる。そして、後加工をより簡略にして、車輪支持用転がり軸受ユニットを構成する外輪の製造コストをより一層低減できる。
Production method of the present invention, radially outward from the plurality of circumferential locations of the outer peripheral surface, if the tubular member having a plurality of protrusions projecting radially, rolling wheel support, such as shown This is not limited to the outer ring constituting the bearing unit.
Although not shown in the drawing, the structure shown in FIG. 2 is provided with a protruding portion that extends further downward from the inner diameter of the lower end surface of the upper punch 43, and the outer ring on the inner side in the axial direction is provided at the lower end surface portion of the protruding portion. If the second surface pressing portion for forming the track 11b is provided, a double row inner ring raceway or a portion having a shape close to the double row inner ring raceway can be processed on the inner peripheral surface of the second intermediate material. . And post-processing can be simplified more and the manufacturing cost of the outer ring | wheel which comprises the rolling bearing unit for wheel support can be reduced further.

本発明の実施の形態の1例を、加工工程順に示す、断面図及び端面図。Sectional drawing and end elevation which show one example of embodiment of this invention in order of a process process. 側方押し出し加工の実施状況の1例を、加工開始直前の状態と加工終了直後の状態とで示す断面図。Sectional drawing which shows an example of the implementation condition of a side extrusion process with the state just before a process start, and the state immediately after completion | finish of a process. 本発明により側方押し出し加工を実施する状態での、金属材料の移動状況を示す、端面図及び断面図。The end view and sectional drawing which show the movement condition of a metal material in the state which implements a side extrusion process by this invention. 本発明の製造方法の対象となる、突出部を備えた筒状部材の1例である外輪を備えた、車輪支持用転がり軸受ユニットの第1例を、ナックルに組み付けた状態で示す断面図。Sectional drawing which shows the 1st example of the rolling bearing unit for wheel support provided with the outer ring which is an example of the cylindrical member provided with the protrusion part used as the object of the manufacturing method of this invention in the state assembled | attached to the knuckle. 同第2例を示す断面図。Sectional drawing which shows the 2nd example. 先に考えた、車輪支持用転がり軸受ユニットを構成する外輪を側方押し出し加工により造る状態を、加工開始直前の状態と加工終了直後の状態とで示す断面図。Sectional drawing which shows the state which made the outer ring which comprises the wheel bearing rolling bearing unit considered previously by the side extrusion process in the state just before a process start, and the state just after completion | finish of a process. 先に考えた製造方法で生じる欠陥を誇張した状態で示す、車輪支持用転がり軸受ユニットを構成する外輪の端面図及び断面図。The end view and sectional drawing of the outer ring | wheel which comprise the rolling bearing unit for wheel support shown in the state which exaggerated the defect which arises with the manufacturing method considered previously. 上記欠陥が生じる理由を説明する為、金属材料の移動状況を示す、端面図及び断面図。In order to explain the reason why the defect occurs, an end view and a cross-sectional view showing a movement state of the metal material.

1 ホイール
2 ロータ
3 ナックル
4 支持孔
5、5a 車輪支持用ハブユニット
6 外輪
7 ボルト
8、8a ハブ
9 スタッド
10 ナット
11a、11b 外輪軌道
12 結合フランジ
13、13a ハブ本体
14 内輪
15 取付フランジ
16a、16b 内輪軌道
17 小径段部
18 かしめ部
19 転動体
20a、20b シールリング
21 スプライン孔
22 等速ジョイント用外輪
23 スプライン軸
24 ナット
25 下板
26 下側保持筒
27 抑え板
28 中心孔
29、29a マンドレル
30 下側パンチ
31 下側支持ブロック
32 下型
33 中心孔
34 下側凹部
35 面押し部
36 上板
37 上型
38 上側保持筒
39 弾性部材
40 中間素材
41 中心孔
42 上側凹部
43 上側パンチ
44 外径側パンチ
45 内径側パンチ
46、46a 第二中間素材
47 段付部
48 円筒状空間
49 放射状空間
50 凹部
51 素材
52 第三中間素材
53 バリ状余肉部
54 上側マンドレル素子
55 下側マンドレル素子
56 第二弾性部材
57 環状隙間
DESCRIPTION OF SYMBOLS 1 Wheel 2 Rotor 3 Knuckle 4 Support hole 5, 5a Wheel support hub unit 6 Outer ring 7 Bolt 8, 8a Hub 9 Stud 10 Nut 11a, 11b Outer ring track 12 Coupling flange 13, 13a Hub body 14 Inner ring 15 Mounting flange 16a, 16b Inner ring raceway 17 Small diameter step portion 18 Caulking portion 19 Rolling element 20a, 20b Seal ring 21 Spline hole 22 Outer ring for constant velocity joint 23 Spline shaft 24 Nut 25 Lower plate 26 Lower holding cylinder 27 Holding plate 28 Center hole 29, 29a Mandrel 30 Lower punch 31 Lower support block 32 Lower mold 33 Center hole 34 Lower recess 35 Surface pressing part 36 Upper plate 37 Upper mold 38 Upper holding cylinder 39 Elastic member 40 Intermediate material 41 Center hole 42 Upper recess 43 Upper punch 44 Outer diameter Side punch 45 Inner diameter side punch 4 , 46a second intermediate material 47 stepped portion 48 cylindrical space 49 radially space 50 recess 51 Material 52 third intermediate material 53 burr-like excess thickness portions 54 upper mandrel element 55 lower mandrel element 56 second elastic member 57 annular gap

Claims (3)

筒状で金属製の素材の内側にマンドレルを挿入して、この素材が内径側に変形する事を抑えると共に、この素材の周囲に配置された、軸方向に2分割される1対の外径側金型の内周面によりこの素材の外周面の一部を抑えた状態で、この素材を軸方向に圧縮する事により、この素材の外周面の残部で上記両外径側金型の内周面により抑えられていない部分を径方向外方に塑性変形させる側方押出加工により、外周面の円周方向複数箇所から径方向外方に向け、放射方向に突出した複数の突出部を形成する、突出部を備えた筒状部材の製造方法であって、上記マンドレルとして、軸方向に2分割された1対のマンドレル素子を、上記突出部となる部分の内径側部分で突き合わせて成るものを使用し、これら両マンドレル素子を互いに近づく方向に弾性的に押圧しつつ、上記素材を軸方向に圧縮する事により、上記突出部を形成すると同時に、この素材の一部を上記両マンドレル素子の突き合わせ部の外径寄り部分に存在する環状隙間若しくは環状溝に進入させ、この突き合わせ部に対応する部分に径方向内方に突出するバリ状余肉部を形成して中間素材とした後、上記両マンドレル素子を離隔させた状態でこの中間素材をこれら両マンドレル素子同士の間から抜き出してから、上記バリ状余肉部を除去する、突出部を備えた筒状部材の製造方法。 A mandrel is inserted inside a cylindrical metal material to prevent the material from deforming to the inner diameter side, and a pair of outer diameters arranged around the material and divided in two in the axial direction. By compressing this material in the axial direction with a part of the outer peripheral surface of this material held down by the inner peripheral surface of the side mold, the inner part of both outer diameter side molds is retained by the remainder of the outer peripheral surface of this material. the side extrusion to plastically deform the portion not suppressed radially outwards by the peripheral surface, radially outward from the plurality of circumferential locations of the outer peripheral surface, forming a plurality of protrusions projecting radially A method of manufacturing a cylindrical member having a protruding portion, wherein the mandrel is formed by abutting a pair of mandrel elements divided into two in the axial direction at the inner diameter side portion of the protruding portion. The direction of approaching these mandrel elements to each other While elastically pressed, by compressing the material in the axial direction, and at the same time to form the protrusions, the annular gap or present some of this material to the outer径寄Ri portion of the butted portion of both the mandrel element After entering the annular groove and forming an intermediate material by forming a burr-like surplus portion protruding radially inward at the portion corresponding to the abutting portion, the intermediate material is separated with the two mandrel elements separated from each other. A method for producing a cylindrical member having a protrusion, wherein the burr-like surplus portion is removed after being extracted from between these two mandrel elements. 突出部を備えた筒状部材が、車輪支持用転がり軸受ユニットを構成する為の外輪であり、外周面に形成された突出部が、この外輪を懸架装置に結合固定する為のフランジ部である、請求項1に記載した突出部を備えた筒状部材の製造方法。   The cylindrical member provided with the protruding portion is an outer ring for constituting a wheel bearing rolling bearing unit, and the protruding portion formed on the outer peripheral surface is a flange portion for coupling and fixing the outer ring to the suspension device. The manufacturing method of the cylindrical member provided with the protrusion part described in Claim 1. 外輪が、この外輪の内径側に複列に配置された転動体に背面組み合わせ型の接触角を付与する為の複列の外輪軌道を内周面に有するものであり、少なくとも一方のマンドレル素子の外周面により、フランジ部の加工と同時に、上記両外輪軌道のうちの一方の外輪軌道を形成する、請求項2に記載した突出部を備えた筒状部材の製造方法。   The outer ring has a double-row outer ring raceway on the inner peripheral surface for imparting a contact angle of the rear combined type to the rolling elements arranged in a double row on the inner diameter side of the outer ring, and at least one of the mandrel elements The manufacturing method of the cylindrical member provided with the protrusion part according to claim 2, wherein one outer ring raceway of the two outer ring raceways is formed simultaneously with the processing of the flange portion by the outer peripheral surface.
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