JP5053874B2 - Vehicle suspension arm and manufacturing method thereof - Google Patents

Vehicle suspension arm and manufacturing method thereof Download PDF

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JP5053874B2
JP5053874B2 JP2008013637A JP2008013637A JP5053874B2 JP 5053874 B2 JP5053874 B2 JP 5053874B2 JP 2008013637 A JP2008013637 A JP 2008013637A JP 2008013637 A JP2008013637 A JP 2008013637A JP 5053874 B2 JP5053874 B2 JP 5053874B2
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suspension arm
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surface portion
bush
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剛毅 四谷
亮 山内
健市 恩田
祥吾 野末
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Suzuki Motor Co Ltd
Kamitsu Seisakusho Ltd
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Kamitsu Seisakusho Ltd
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本発明は、車両用サスペンションアーム及びその製造方法に関し、さらに詳しくは、アルミニウム合金製の押出形材を二次加工してサスペンションアームを成形する技術に係わるものである。   The present invention relates to a vehicle suspension arm and a method for manufacturing the same, and more particularly to a technique for forming a suspension arm by secondary processing of an extruded shape made of aluminum alloy.

従来、自動車等の車両のサスペンションアームは、比較的安価な鉄鋼材料を用いてプレス成形と溶接を併用して成形するのが一般的であった(例えば、特許文献1参照)。しかし、近年、C02削減要請の高まりとともに更なる軽量化が求められ、サスペンションアームのアルミ化が進行している。サスペンションアームをアルミニウム合金化する方法としては、鋳造による方法(例えば、特許文献2参照)や中空の押出形材を二次成形する方法(例えば、特許文献3、4参照)が知られている。 Conventionally, a suspension arm of a vehicle such as an automobile is generally formed by using a relatively inexpensive steel material in combination with press molding and welding (for example, see Patent Document 1). However, in recent years, further weight reduction is required with increasing C0 2 reduction request, aluminized of the suspension arm is in progress. As a method for forming the suspension arm into an aluminum alloy, a casting method (for example, see Patent Document 2) and a method for secondary forming a hollow extruded shape (for example, see Patent Documents 3 and 4) are known.

部品のアルミニウム合金化を図る場合、やはり市場の要求から、材料費や製造工程でのコスト増に伴う部品単価の上昇を極力抑える必要がある。低コストでサスペンションアームをアルミニウム合金化するには、中空の押出形材を溶接工程なしで二次成形する方法が最も有利である。   When trying to make an aluminum alloy of parts, it is necessary to suppress as much as possible the increase in the unit price of the parts due to the increase in material costs and costs in the manufacturing process due to market demands. In order to alloy the suspension arm with an aluminum alloy at a low cost, the method of secondary forming a hollow extruded profile without a welding process is most advantageous.

ところで、自動車のサスペンションアームは、基端部において車体構造に揺動可能に枢支され、該基端部よりも幅狭の先端部には、車輪を支持するナックルが連結されており、さらに、マルチリンク式やダブルウィシュボーン式のリアサスペンションにおけるロアアームでは、アーム長手方向の中間部にコイルスプリングの受け面が設けられている。   By the way, the suspension arm of the automobile is pivotally supported by the vehicle body structure at the base end portion so as to be swingable, and a knuckle for supporting the wheel is connected to the tip end portion narrower than the base end portion. In a lower arm in a multi-link type or double wishbone type rear suspension, a receiving surface of a coil spring is provided at an intermediate portion in the arm longitudinal direction.

この受け面は、コイルスプリングの径よりも大きくする必要があるため、一般に、ロアアームの中間部は、先端部や基端部に比べて幅広に構成される。したがって、ロアアームは、その長手方向に沿って断面形状が大きく変化しており、このようなロアアームを、長手方向に一様な断面形状をなす押出形材から成形する場合、コイルスプリングの受け部に対応した幅を有する押出形材を用い、その端部を幅方向に圧縮する方法や、逆に、押出形材の中間部を幅方向に拡開してコイルスプリングの受け部を形成する方法が想定される。   Since this receiving surface needs to be larger than the diameter of the coil spring, the intermediate portion of the lower arm is generally configured wider than the distal end portion and the proximal end portion. Therefore, the cross-sectional shape of the lower arm is greatly changed along the longitudinal direction thereof, and when such a lower arm is formed from an extruded profile having a uniform cross-sectional shape in the longitudinal direction, the lower arm has a coil spring receiving portion. There is a method of using an extruded profile having a corresponding width and compressing its end in the width direction, or conversely, a method of forming the receiving portion of the coil spring by expanding the intermediate portion of the extruded profile in the width direction. is assumed.

このうち、押出形材の中間部を拡開する方法は減肉を伴い、高強度を要求されるコイルスプリング受け部の強度を確保することが困難である。したがって、押出形材の端部を幅方向に圧縮する方法が有利であるが、押出形材の端部をプレスで両側面からそのまま潰す場合、変形位置が安定せず精度を確保するのが困難である。ロアアーム両端の取り付け部には、高い寸法精度が求められるが、この精度要求に答えることができない。   Among these methods, the method of expanding the intermediate portion of the extruded profile is accompanied by thinning, and it is difficult to ensure the strength of the coil spring receiving portion that requires high strength. Therefore, the method of compressing the end of the extruded profile in the width direction is advantageous, but when the end of the extruded profile is crushed as it is from both sides with a press, the deformation position is not stable and it is difficult to ensure accuracy. It is. High dimensional accuracy is required for the attachment portions at both ends of the lower arm, but this accuracy requirement cannot be met.

そこで、特許文献3では、押出形材の上面および下面の板厚を両側面の板厚よりも小さくすることによって塑性変形が上面および下面の中央部に誘導されるようにしている。しかし、押出形材の上下面を薄肉化すれば、全体的な強度が不足し、上下方向の曲げ入力やコイルスプリングからの下方向の入力に耐えることができない。   Therefore, in Patent Document 3, plastic deformation is induced in the central portion of the upper surface and the lower surface by making the plate thickness of the upper surface and the lower surface of the extruded profile smaller than the plate thickness of both sides. However, if the upper and lower surfaces of the extruded profile are made thinner, the overall strength is insufficient, and it is not possible to withstand vertical bending input and downward input from a coil spring.

特開2002−316228号公報JP 2002-316228 A 特許第3873641号公報Japanese Patent No. 38733641 国際特許公開01/32979号公報International Patent Publication No. 01/32979 国際特許公開2005/002890号公報International Patent Publication No. 2005/002890

上述した押出形材の端部をプレスで両側面からそのまま潰す方法に対して、押出形材端部の中央を長手方向にスリット状に切除し、この切除分を圧縮代としてプレスで両側面から圧縮すれば、変形位置が安定し寸法精度を確保することができる。しかし、この方法では、アーム端部の両側面が分断されてしまうため、サスペンションアームに必要なねじり剛性を確保することが困難になる。   In contrast to the method of crushing the edge of the extruded profile from the both sides with a press, the center of the extruded profile is cut into a slit in the longitudinal direction, and this cut is used as a compression allowance from both sides with a press. If the compression is performed, the deformation position is stabilized and the dimensional accuracy can be secured. However, this method divides both side surfaces of the arm end portion, making it difficult to ensure the torsional rigidity necessary for the suspension arm.

また、サスペンションアームをアルミニウム合金製押出形材で形成する場合の別の課題として、ブッシュの保持力の確保がある。一般に、サスペンションアームの基端部は、車軸側から入力される振動や三次元的な変位の吸収を目的としてブッシュを介して車体構造に揺動可能に枢支されるが、アルミニウム合金製の押出形材でサスペンションアームを構成する場合、押出形材の打抜き孔に圧入されたブッシュは、押出形材側面の板厚分だけで保持されることになり、圧入後におけるブッシュの保持力を確保するのが難しい。   Another problem when the suspension arm is formed of an aluminum alloy extruded profile is securing the holding force of the bush. Generally, the base end of the suspension arm is pivotally supported by the vehicle body structure via a bush for the purpose of absorbing vibration and three-dimensional displacement input from the axle side. When the suspension arm is composed of a profile, the bush that is press-fitted into the punched hole of the extruded profile will be held only by the thickness of the side of the extruded profile, ensuring the holding force of the bush after press-fitting. It is difficult.

特に、アルミニウム合金製のサスペンションアームに対して、アルミニウム合金製の外筒を有するブッシュを圧入する場合は、かじりの問題から、圧入代を大きくすることができず、保持力の確保が一層困難である。また、ブッシュの外筒を鉄製とした場合、アルミニウム合金製のサスペンションアームとの間で電食を生じる問題がある。   In particular, when a bush having an aluminum alloy outer cylinder is press-fitted into an aluminum alloy suspension arm, the press-fitting allowance cannot be increased due to galling problems, and it is more difficult to secure a holding force. is there. In addition, when the outer cylinder of the bush is made of iron, there is a problem that electric corrosion occurs between the suspension arm made of aluminum alloy.

本発明はこのような実状に鑑みてなされたものであって、その目的は、アルミニウム合金製の押出形材から低コストでサスペンションアームを成形できるとともに、車体構造側または車軸側に回動可能に連結される連結部、特に、車体構造側に枢支されるアーム基端部に必要な寸法精度およびねじり剛性が得られ、かつ、ブッシュ外筒に対する保持力にも優れた車両用サスペンションアーム及びその製造方法を提供することにある。   The present invention has been made in view of such a situation, and an object of the present invention is to form a suspension arm from an extruded shape made of an aluminum alloy at a low cost and to be rotatable to the vehicle body structure side or the axle side. A suspension arm for a vehicle that provides the required dimensional accuracy and torsional rigidity for the connecting portion to be connected, particularly the arm base end portion pivotally supported on the vehicle body structure side, and also has excellent holding force for the bushing outer cylinder, and It is to provide a manufacturing method.

上記課題を解決するために、本発明は、
上面部と下面部とが少なくとも2つの側壁部で連結され長手方向に一様な断面略四角形状をなす中空のアルミニウム合金製押出形材からの二次加工によって形成された車両用サスペンションアームであって、
前記押出形材の一端部が、その縁端から前記上面部および前記下面部の幅方向中央部に長手方向に延びる上下同形のスリット状の切欠部で分断され、その両側部分が、前記切欠部を変形代とした両側方からの曲げ加工で突き合わされて幅狭に構成されるとともに、該幅狭の両側部分で前記各側壁部を貫通する貫通孔に円筒状の連結部材が嵌挿され、かつ、前記連結部材の前記各貫通孔から側方に突出した両端部が拡開され、該拡開端部のかしめによって前記両側部分が一体に連結されており、前記一端部が、前記連結部材を介して車体構造側または車軸側に回動可能に連結されていることを特徴とする車両用サスペンションアームにある。
In order to solve the above problems, the present invention provides:
A suspension arm for a vehicle formed by secondary processing from a hollow aluminum alloy extruded shape having an upper surface portion and a lower surface portion connected by at least two side wall portions and having a substantially rectangular cross section in the longitudinal direction. And
One end portion of the extruded shape member is divided by a slit-shaped notch portion having an upper and lower shape that extends in the longitudinal direction from the edge to the center portion in the width direction of the upper surface portion and the lower surface portion, and both side portions thereof are the notch portions. Is formed with a narrow width by being abutted by bending from both sides with a deformation margin, and a cylindrical connecting member is inserted into a through-hole penetrating each side wall portion at both narrow side portions, And the both ends which protruded from the said through-hole of the said connection member to the side are expanded, the said both side parts are integrally connected by the crimping of this said expansion end part, and the said one end part connects the said connection member. The vehicle suspension arm is rotatably connected to the vehicle body structure side or the axle side.

また、前記連結部材の前記両端部が、周方向に所定のピッチ複数箇所にて拡開されていることが好適である。さらに、前記連結部材が、内筒と外筒とそれらの間に介在するゴム部とで構成されるブッシュであり、前記ブッシュの前記外筒が前記貫通孔に嵌挿され、かつ、前記外筒の両端部が拡開されており、前記押出形材の一端部が、前記ブッシュを介して車体構造側に揺動可能に枢支されていることが好適である。さらに、前記押出形材の前記上面部が、前記各側壁部との接続部を越えて幅方向に張出しており、前記両側部分を含まない前記押出形材の長手方向中間部に、コイルスプリングの受け部が設けられていることが好適である。 Moreover, it is preferable that the both end portions of the connecting member are expanded at a plurality of locations at a predetermined pitch in the circumferential direction. Further, the connecting member is a bush composed of an inner cylinder, an outer cylinder, and a rubber portion interposed therebetween, and the outer cylinder of the bush is fitted into the through hole, and the outer cylinder It is preferable that both end portions of the extruded shape member are widened, and one end portion of the extruded shape member is pivotally supported on the vehicle body structure side via the bush. Further, the upper surface portion of the extruded shape member extends in the width direction beyond the connection portion with each of the side wall portions, and a coil spring is disposed at a longitudinal intermediate portion of the extruded shape member not including the both side portions. It is preferable that a receiving portion is provided.

また、本発明は、上記車両用サスペンションアームの製造方法として、
前記押出形材の一端部から、前記上面部および前記下面部の幅方向中央部を長手方向に上下同形のスリット状に切欠する工程と、
前記スリット状の切欠によって分断された前記押出形材一端部の両側部分を、両側方から曲げ加工して突き合わせる工程と、
前記押出形材一端部に前記各側壁部を貫通する貫通孔を穿設する工程と、
前記各側壁部の前記貫通孔に円筒状連結部材を嵌挿する工程と、
前記連結部材の前記各貫通孔から側方に突出した両端部を拡開してかしめ、前記両側部分を一体に連結する工程と、を含む製造方法を採用した。
Further, the present invention provides a method for manufacturing the above vehicle suspension arm,
From the one end portion of the extruded profile, a step of cutting the upper surface portion and the width direction center portion of the lower surface portion into a slit shape having an upper and lower shape in the longitudinal direction;
Bending both sides of the one end portion of the extruded profile divided by the slit-shaped notch, and abutting them from both sides; and
Drilling a through-hole penetrating each side wall at one end of the extruded profile;
Inserting a cylindrical connecting member into the through hole of each side wall; and
The manufacturing method includes a step of expanding and caulking both end portions protruding laterally from the respective through holes of the connecting member, and connecting the both side portions integrally.

さらに、前記両側部分を一体に連結する工程が、前記連結部材の前記両端部をその周方向に所定のピッチ複数箇所にて拡開してかしめることを含むことが好適である。 Furthermore, it is preferable that the step of integrally connecting the both side portions includes expanding and caulking the both end portions of the connecting member at a predetermined pitch in the circumferential direction.

本発明の車両用サスペンションアームは上記の通り構成されているので、一様な断面略四角形状をなす中空のアルミニウム合金製押出形材から、切除および曲げ加工という少ない工数の簡素な加工による必要最小限の塑性変形で、幅狭の端部を精度良く形成できるとともに、スリット状切欠部で分断されたアームの両側部分が、連結部材の拡開端部のかしめによって強固に連結されることで、サスペンションアームとして必要なねじり剛性および強度が確保されており、サスペンションアームの製造コストを低減しつつ軽量化するうえで有利である。 Since the suspension arm for a vehicle according to the present invention is configured as described above, it is the minimum necessary by a simple processing with a small number of man-hours such as cutting and bending from a hollow aluminum alloy extruded shape having a uniform square cross section. With the limited plastic deformation, the narrow end can be accurately formed, and both sides of the arm divided by the slit-shaped notch are firmly connected by caulking of the expanding end of the connecting member, so that the suspension The torsional rigidity and strength necessary for the arm are ensured, which is advantageous in reducing the weight while reducing the manufacturing cost of the suspension arm.

また、前記連結部材の前記両端部が、周方向に所定のピッチ複数箇所にて拡開されている態様では、連結部材の拡開端部が、単純な円形状ではなく花弁状あるいは多角形状をなすことよって、拡開端部自体の剛性が上昇し、連結部材の抜脱荷重が向上することは勿論、サスペンションアーム全体のねじり剛性が大幅に向上することになる。 Moreover, in the aspect in which the both end portions of the connecting member are expanded at a plurality of locations at a predetermined pitch in the circumferential direction, the expanding end portion of the connecting member has a petal shape or a polygonal shape instead of a simple circular shape. By doing so, the rigidity of the expanded end portion itself is increased, and the torsional rigidity of the entire suspension arm is greatly improved as well as the removal load of the connecting member is improved.

また、前記連結部材が、内筒と外筒とそれらの間に介在するゴム部とで構成されるブッシュであり、前記ブッシュの前記外筒が前記貫通孔に嵌挿され、かつ、前記外筒の両端部が拡開されている態様では、サスペンションアームのかしめとブッシュのかしめの両方を兼ねる構造となり、特別な連結部材を省くことができ、かつ、少ない工数でサスペンションアームを製造可能であるとともに、サスペンションアームにブッシュを強固に連結でき、ブッシュ外筒に対する保持力にも優れている。また、ブッシュ外筒を圧入する必要がないので、ブッシュ外筒をアルミニウム合金製としても、かじりの問題を生じることがなく、ブッシュ外筒をアルミニウム合金製とすることで異種金属接触に伴う電食を防止できる。   Further, the connecting member is a bush composed of an inner cylinder, an outer cylinder, and a rubber portion interposed therebetween, and the outer cylinder of the bush is fitted into the through hole, and the outer cylinder In the embodiment in which both ends of the arm are widened, both the caulking of the suspension arm and the caulking of the bush are formed, a special connecting member can be omitted, and the suspension arm can be manufactured with less man-hours. The bush can be firmly connected to the suspension arm, and the holding force to the bushing outer cylinder is excellent. In addition, since it is not necessary to press fit the bushing outer cylinder, there is no galling problem even if the bushing outer cylinder is made of an aluminum alloy, and the bushing outer cylinder is made of an aluminum alloy. Can be prevented.

さらに、前記押出形材の前記上面部が、前記各側壁部との接続部を越えて幅方向に張出しており、前記押出形材の長手方向中間部にコイルスプリングの受け部が設けられている態様では、張出部分によって受け部に必要な幅が確保されるとともに、サスペンションアーム自体の補強が図れ、大断面が必要なコイルスプリング受け部と小断面が必要な車体構造側または車軸側との連結端部を一様な断面略四角形状をなす中空のアルミニウム合金製押出形材に形成するうえで有利である。   Further, the upper surface portion of the extruded shape member extends in the width direction beyond the connection portion with each of the side wall portions, and a receiving portion of a coil spring is provided in the longitudinal intermediate portion of the extruded shape member. In the aspect, the projecting portion secures a necessary width in the receiving portion, and the suspension arm itself can be reinforced, and the coil spring receiving portion requiring a large cross section and the vehicle body structure side or the axle side requiring a small cross section are provided. This is advantageous when the connecting end portion is formed into a hollow aluminum alloy extruded shape having a substantially square cross section.

本発明は、上記のようなサスペンションアームの製造方法採用したので、押出形材一端部の両側部分を両側方からのプレスによる曲げ加工で無理なく塑性変形させることができ、寸法精度に優れた連結端部を形成可能であるとともに、分断された両側部分を、連結部材の嵌合とその端部の拡開及びかしめによって強固に一体化させ、サスペンションアームに必要なねじり剛性を確保でき、サスペンションアームの製造コストを低減しつつ軽量化するうえで有利である。また、上記各工程は冷間加工のみで行なうことができるため、工程間の温度調節が不要であり、連続加工や工程の自動化に最適である。 The present invention, since the adopted method for manufacturing a suspension arm as described above, can be plastically deformed without difficulty in bending by a press of the both side portions of the extruded shape member end from both sides, excellent dimensional accuracy The connecting end can be formed, and both divided parts are firmly integrated by fitting the connecting member and expanding and caulking the end to secure the torsional rigidity required for the suspension arm. This is advantageous in reducing the weight while reducing the manufacturing cost of the arm. Moreover, since each said process can be performed only by cold processing, the temperature adjustment between processes is unnecessary and it is the best for continuous processing and automation of a process.

また、前記両側部分を一体に連結する工程が、前記連結部材の前記両端部をその周方向に所定のピッチで間欠的に複数箇所にて拡開してかしめることを含むことにより、連結部材両端部の拡開及びかしめ変形の少なくとも初期において、周方向の数箇所に圧縮応力が集中するため、連結部材両端部の拡開変形に要する圧縮荷重を低減できるとともに、連結部材の中央部など非変形部分に付加される応力を低減でき、不要な変形を防止できる。   Further, the step of integrally connecting the both side portions includes expanding and caulking the both end portions of the connecting member at a plurality of locations intermittently at a predetermined pitch in the circumferential direction. At least at the initial stage of expansion and caulking deformation of both ends, compressive stress is concentrated in several places in the circumferential direction, so that it is possible to reduce the compressive load required for expansion deformation of both ends of the connecting member, The stress applied to the deformed portion can be reduced, and unnecessary deformation can be prevented.

すなわち、仮に、円盤状または円錐状の押圧子により、連結部材の両端部を周方向全体に亘って拡開する場合には、同等の拡開量を得るのに連結部材両端部の周長変化が大きくなり、外周部の亀裂が生じ易くなるが、連結部材の両端部を周方向に間欠的に拡開する本発明の方法により、拡開端部における周長変化を最小限に抑えつつ、両端部の拡開量を大きく確保することができ、連結強度を向上させるうえで有利である。   That is, if both ends of the connecting member are expanded over the entire circumferential direction by means of a disc-shaped or conical presser, the peripheral length change of both ends of the connecting member is obtained to obtain an equivalent expansion amount. The outer peripheral portion is likely to crack, but the both ends of the connecting member are intermittently expanded in the circumferential direction by the method of the present invention while minimizing the change in the peripheral length at the expanded end portion. A large amount of expansion of the portion can be ensured, which is advantageous in improving the connection strength.

以下、本発明の実施の形態について、図面を参照しながら詳細に説明する。
図1は、本発明に係わる車両用サスペンションアームを、自動車のリアサスペンションにおけるロアアーム1として実施した実施形態を示している。図において、リアサスペンションは、車輪3を回動自在に支持するナックル4が、ロアアーム1およびアッパーアーム2を含む複数のリンクを介して車体構造5に揺動可能に連結されたマルチリンク式サスペンションであり、ロアアーム1の中間部13と車体構造5との間にコイルスプリング6が介装されている。ロアアーム1の基端部11は、ブッシュ7を介して車体構造5に揺動可能に枢支され、一方、ロアアーム1の先端部12は、ナックル4の下部に回動可能に連結されている。
Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
FIG. 1 shows an embodiment in which a vehicle suspension arm according to the present invention is implemented as a lower arm 1 in a rear suspension of an automobile. In the figure, the rear suspension is a multi-link suspension in which a knuckle 4 that rotatably supports a wheel 3 is swingably connected to a vehicle body structure 5 via a plurality of links including a lower arm 1 and an upper arm 2. The coil spring 6 is interposed between the intermediate portion 13 of the lower arm 1 and the vehicle body structure 5. A base end portion 11 of the lower arm 1 is pivotally supported by the vehicle body structure 5 via a bush 7, while a distal end portion 12 of the lower arm 1 is rotatably connected to a lower portion of the knuckle 4.

図2は、ロアアーム1を示す斜視図であり、先端部12および中間部13に比べて幅狭の基端部11には、図3に示すように、ブッシュ7が側方に貫通した状態で固定され、車体構造5との回動連結部を構成している。先端部12は、U字状の切欠部120によって二又に分岐したフォーク状に形成され、その両側部分121、122を側方に貫通する貫通孔20がそれぞれに穿設され、ナックル4との回動連結部を構成している。また、中間部13には、コイルスプリング6の受け部材(13)が設けられている。   FIG. 2 is a perspective view showing the lower arm 1. In the base end portion 11 which is narrower than the distal end portion 12 and the intermediate portion 13, as shown in FIG. It is fixed and constitutes a rotation connecting part with the vehicle body structure 5. The front end portion 12 is formed in a fork shape bifurcated by a U-shaped cutout portion 120, and through holes 20 penetrating the both side portions 121, 122 laterally are respectively drilled. It constitutes a rotating connecting part. The intermediate portion 13 is provided with a receiving member (13) for the coil spring 6.

ロアアーム1は、図4〜図7に示すように、長手方向に一様な断面略四角形状をなす中空のアルミニウム合金製の押出形材1Aを二次加工することによって形成される。素材となる押出形材1Aは、図6に示すように、平坦な上面部14と下面部15とが、それらの両側部で2つの側壁部16、17によって連結された略四角筒状を基本としているが、上面部14の両側14a、14aが、前記各側壁部16、17との接続部を越えて幅方向に張出しており、上面部14の幅が下面部15に比べて広くなっている。   As shown in FIGS. 4 to 7, the lower arm 1 is formed by secondary processing a hollow aluminum alloy extruded profile 1 </ b> A having a substantially rectangular cross section in the longitudinal direction. As shown in FIG. 6, the extruded profile 1A as a raw material has a substantially square cylindrical shape in which a flat upper surface portion 14 and a lower surface portion 15 are connected by two side wall portions 16 and 17 on both sides thereof. However, both sides 14 a, 14 a of the upper surface portion 14 extend in the width direction beyond the connection portions with the side wall portions 16, 17, and the width of the upper surface portion 14 is wider than the lower surface portion 15. Yes.

このような押出形材1Aから、ロアアーム1を形成するに際しては、先ず、図4に示すように、押出形材1Aの基端部11および先端部12の縁端から、上面部14および下面部15の幅方向中央部を、長手方向に沿ってスリット状に切欠し、U字状の切欠部110、120を形成する。図7(a)は、切欠部110を形成した基端部11の断面を示している。   When forming the lower arm 1 from such an extruded profile 1A, first, as shown in FIG. 4, from the edge of the base end 11 and the distal end 12 of the extruded profile 1A, the upper surface portion 14 and the lower surface portion. 15 center portions in the width direction are cut out in a slit shape along the longitudinal direction to form U-shaped cutout portions 110 and 120. FIG. 7A shows a cross section of the base end portion 11 in which the notch portion 110 is formed.

次いで、図5に矢印で示すように、切欠部110によって分断された基端部11の両側部分111、112を両側方からプレスで圧縮して曲げ加工を行い、切欠部110の対向する縁部を突き合わせる。この際、両側部分111、112には、それらの基部を中心とした限られた範囲に緩やかな曲げ応力および剪断応力が付加されるのみであり、最小限の塑性変形で成形されるため、寸法精度や強度の低下を生じることがない。図7(a)は、両側方から圧縮され幅狭になった基端部11の断面を示している。なお、図1に示すように、押出形材1Bを必要に応じて厚さ方向に湾曲させる曲げ加工を行なっても良い。   Next, as shown by arrows in FIG. 5, both side portions 111, 112 of the base end portion 11 divided by the notch portion 110 are compressed by pressing from both sides with a press, and the opposite edge portions of the notch portion 110 are bent. Match. At this time, the side portions 111 and 112 are only subjected to gentle bending stress and shear stress within a limited range centered on their base portions, and are formed with a minimum plastic deformation. There is no reduction in accuracy or strength. FIG. 7A shows a cross section of the base end portion 11 which is compressed from both sides and becomes narrower. In addition, as shown in FIG. 1, you may perform the bending process which curves the extrusion-shaped material 1B in the thickness direction as needed.

さらに、突き合わされた両側部分111、112の側壁部16、17を貫通して貫通孔10、10を穿設するとともに、先端部12においても、両側部分121、122の側壁部16、17を貫通して貫通孔20、20を穿設する。なお、先端部12の貫通孔20、20は、切欠部120の形成前に穿設しておいても良い。   Further, the through holes 10 and 10 are formed through the side wall portions 16 and 17 of the both side portions 111 and 112 that are abutted, and the side wall portions 16 and 17 of the both side portions 121 and 122 are also penetrated at the distal end portion 12. Then, the through holes 20 are formed. Note that the through holes 20 and 20 of the distal end portion 12 may be drilled before the cutout portion 120 is formed.

次に、基端部11の貫通孔10、10にブッシュ7を嵌挿する。ブッシュ7は、図7(c)に示すように、外筒71と、その内側に同軸に配置された内筒72と、それらの間に充填されたゴム部73で構成され、内筒72は外筒71よりも長く、外筒71の端部から両側に突出している。ブッシュ7の外筒71は、押出形材1Aと同様にアルミニウム合金で構成されている。ブッシュ7は、図8(a)に示すように、貫通孔10、10に貫通した状態に嵌入され、ブッシュ7の外筒71および内筒72の両端部は、両側部分111、112の側壁部16、17から側方に突出している。   Next, the bush 7 is fitted into the through holes 10 and 10 of the base end portion 11. As shown in FIG. 7 (c), the bush 7 is composed of an outer cylinder 71, an inner cylinder 72 disposed coaxially with the outer cylinder 71, and a rubber portion 73 filled between the inner cylinder 72 and the inner cylinder 72. It is longer than the outer cylinder 71 and protrudes from the end of the outer cylinder 71 to both sides. The outer cylinder 71 of the bush 7 is made of an aluminum alloy like the extruded shape member 1A. As shown in FIG. 8A, the bush 7 is inserted into the through holes 10 and 10, and both end portions of the outer cylinder 71 and the inner cylinder 72 of the bush 7 are side wall portions of both side portions 111 and 112. 16 and 17 project sideways.

次いで、図8(a)に示すように、ブッシュ7の外筒71の突出した両端部71aを、両側方から一対の押圧子8、8で挟んで加圧し、図8(b)に示すように、両端部71aを拡開してかしめることにより(71c)、突き合わせられた基端部11の両側部分111、112をブッシュ7の外筒71で連結するとともに、ブッシュ7を基端部11の貫通孔10、10に固定する。   Next, as shown in FIG. 8 (a), the projecting end portions 71a of the outer cylinder 71 of the bush 7 are pressed between the pair of pressing elements 8, 8 from both sides, and as shown in FIG. 8 (b). In addition, by expanding and crimping both end portions 71a (71c), both side portions 111 and 112 of the abutted base end portion 11 are connected by the outer cylinder 71 of the bush 7 and the bush 7 is connected to the base end portion 11 The through holes 10 and 10 are fixed.

ブッシュ外筒71の拡開かしめに使用する押圧子8は、ブッシュ内筒72と干渉せずにブッシュ外筒71を加圧できるように、少なくとも先端部が、中央に空洞80を有する中空円筒状に形成されている。押圧子8の押圧面は単純な平面または円錐面とすることもできるが、図9(a)および(b)に示すように、端面82の周方向に所定のピッチで間欠的に突設された複数(図示例では4箇所)の凸部81を備えることが好ましい。   The pusher 8 used for expanding the bushing outer cylinder 71 is a hollow cylinder having at least a tip having a cavity 80 at the center so that the bushing outer cylinder 71 can be pressurized without interfering with the bushing inner cylinder 72. Is formed. The pressing surface of the pressing element 8 can be a simple flat surface or a conical surface, but as shown in FIGS. 9A and 9B, it is intermittently projected at a predetermined pitch in the circumferential direction of the end surface 82. It is preferable to provide a plurality of (four in the illustrated example) convex portions 81.

このような押圧子8を用いてブッシュ外筒71を加圧することにより、外筒両端部71aの拡開部71cが、周方向に所定のピッチで間欠的な数箇所(図示例では4箇所)となり、図11に示すように、拡開部71cは花弁状または多角形状となる。これにより、全周を均等に拡開する場合に比べて、拡開部71cにおける周長変化を最小限に抑え、図11におけるdC−dBで示される拡開量を大きく確保することができ、拡開かしめによる連結強度を向上できる。 By pressurizing the bush outer cylinder 71 using such a presser 8, the expanded portions 71c of the outer cylinder both ends 71a are intermittently provided at a predetermined pitch in the circumferential direction (four locations in the illustrated example). Thus, as shown in FIG. 11, the expanded portion 71c has a petal shape or a polygonal shape. Thus, as compared with the case of uniformly expanding the entire periphery, to minimize changes in the peripheral length of the expanding portion 71c, it is possible to ensure a large amount of expansion indicated by d C -d B in FIG. 11 It is possible to improve the connection strength due to the expansion.

また、外筒両端部71aの拡開及びかしめ変形の少なくとも初期において、周方向の数箇所(図示例では4箇所)に圧縮応力が集中するため、この部分において比較的低い荷重で塑性変形が開始され、拡開変形に要する圧縮荷重を低減できるとともに、ブッシュ外筒71の中央部など非変形部分に付加される応力を低減でき、ブッシュ7の不要な変形を防止できる。   Further, at least in the initial stage of the expansion and caulking deformation of both ends 71a of the outer cylinder, the compressive stress concentrates at several places in the circumferential direction (four places in the illustrated example), so plastic deformation starts at a relatively low load in this part. In addition, the compressive load required for the expansion deformation can be reduced, the stress applied to the non-deformed portion such as the central portion of the bush outer cylinder 71 can be reduced, and unnecessary deformation of the bush 7 can be prevented.

さらに、図10(a)および(b)に示すように、端面82′の周方向に所定のピッチで間欠的に突設されたそれぞれの凸部81′が、中心軸に向かい突出する傾斜角θを有する押圧子8′を用いれば、外筒両端部71aの拡開変形が傾斜面によって誘導され、拡開変形に要する圧縮荷重を一層低減できるとともに、拡開変形時における中心のずれが補正される利点もある。   Further, as shown in FIGS. 10 (a) and 10 (b), the inclination angles at which the respective convex portions 81 ′ projecting intermittently at a predetermined pitch in the circumferential direction of the end surface 82 ′ project toward the central axis. If the pressing element 8 'having θ is used, the expansion deformation of the outer cylinder both ends 71a is induced by the inclined surface, and the compressive load required for the expansion deformation can be further reduced, and the center shift during the expansion deformation is corrected. There are also benefits.

なお、上記実施形態のブッシュ外筒71では、4箇所の拡開部71cが、周方向に90度間隔で配設される場合を示したが、拡開部71cの設置数および配置はこれ以外とすることもできる。上述のように拡開部71cが周方向に所定のピッチで間欠的に配設され、すなわち、周方向に対称性を有する基本的類型としては、(1)拡開部71cが周方向に等間隔で配設される態様と、(2)拡開部71cがブッシュ外筒71の中心を通り周方向に等間隔で設定された複数の対称軸それぞれについて対称に配置される態様とがある。例えば、周方向に120度間隔で設定された3本の対称軸について対称となるように±10度ずれた配置がこれに該当し、当然ながら、加工に用いる押圧子8、8′の凸部81、81′もこれに対応した配置となる。   In addition, in the bush outer cylinder 71 of the said embodiment, although the case where the four expansion parts 71c were arrange | positioned by the 90 degree space | interval in the circumferential direction was shown, the installation number and arrangement | positioning of the expansion parts 71c are other than this. It can also be. As described above, the expanded portions 71c are intermittently arranged at a predetermined pitch in the circumferential direction. That is, as a basic type having symmetry in the circumferential direction, (1) the expanded portion 71c is circumferentially or the like. There are a mode of being arranged at intervals and a mode of (2) the expanding portions 71c being arranged symmetrically with respect to each of a plurality of symmetry axes set at equal intervals in the circumferential direction through the center of the bushing outer cylinder 71. For example, this is an arrangement that is shifted by ± 10 degrees so as to be symmetric with respect to three symmetry axes set at intervals of 120 degrees in the circumferential direction, and of course, the convex portions of the pressers 8 and 8 'used for processing. 81 and 81 'are also arranged corresponding to this.

次に、本発明のサスペンションアーム(1)におけるブッシュ7の固定強度およびアーム基端部11の両側部分111、112の連結強度を検証するために、ブッシュ外筒71と貫通孔10の嵌合公差と、ブッシュ外筒71の抜脱荷重との関係を調べる実験を以下のように行なった。   Next, in order to verify the fixing strength of the bush 7 and the connection strength of both side portions 111 and 112 of the arm base end portion 11 in the suspension arm (1) of the present invention, the fitting tolerance between the bush outer cylinder 71 and the through hole 10 is confirmed. And an experiment for examining the relationship between the load and removal load of the bushing outer cylinder 71 were performed as follows.

実験では、板厚2mmのアルミニウム合金製のブッシュ外筒を用い、ブッシュ外筒のアーム側壁部からの突出量a=6.0mm、ブッシュ外筒の拡開量(dC−dB)は、0.8〜1.4mmとして、図9に示した押圧子8(傾斜角θ=0°)を用いて拡開かしめを行なった場合と、図10に示した押圧子8′(傾斜角θ=10°)を用いて拡開かしめを行なった場合について、ブッシュ外筒の外径(dB)と貫通孔内径(dH)との嵌合公差(dB−dH)を、−0.3mm(緩み嵌め)〜+0.3mm(締まり嵌め)の間で0.1mmずつ変化させてブッシュ外筒の引き抜き試験を行い、抜脱荷重(kN)を測定した。また、比較のために、拡開かしめを行なわずにブッシュ外筒を単に嵌入(圧入)した場合についても同様の測定を行なった。 In the experiment, a bush outer cylinder made of an aluminum alloy having a thickness of 2 mm was used. The amount of protrusion a = 6.0 mm from the arm side wall of the bush outer cylinder, and the amount of expansion of the bush outer cylinder (d C −d B ) In the case of 0.8 to 1.4 mm, when the spreader is opened using the presser 8 (inclination angle θ = 0 °) shown in FIG. 9, and the presser 8 ′ (inclination angle θ shown in FIG. 10). = 10 °), the fitting tolerance (d B −d H ) between the outer diameter (d B ) of the bushing outer cylinder and the inner diameter (d H ) of the through hole is −0. The bushing outer cylinder was pulled out by varying 0.1 mm between 3 mm (loose fitting) and +0.3 mm (tightening), and the removal load (kN) was measured. For comparison, the same measurement was performed when the bushing outer cylinder was simply inserted (press-fitted) without being expanded.

図12は、実験結果を示すグラフである。この結果から、本発明の方法に基づき拡開かしめを行なった場合には、嵌合公差がマイナスすなわち緩み嵌めの場合においても充分な固定強度が得られ、嵌合公差の許容範囲が広く、安定的な品質が得られることを示唆している。締まり嵌めの範囲で固定強度に頭打ちの傾向が見られる。単に圧入のみ行なった場合には充分な固定強度は得られず、嵌合公差0.2mm以上では逆に固定強度が減少している。   FIG. 12 is a graph showing experimental results. From this result, when the spread is performed based on the method of the present invention, sufficient fixing strength is obtained even when the fitting tolerance is negative, that is, loose fitting, the tolerance range of the fitting tolerance is wide and stable. This suggests that quality can be obtained. There is a tendency for the fixed strength to peak within the range of the interference fit. When only press-fitting is performed, sufficient fixing strength cannot be obtained. On the contrary, when the fitting tolerance is 0.2 mm or more, the fixing strength decreases.

また、凸部に傾斜が有る押圧子8′では、抜脱荷重の測定値が安定しているのに対し、傾斜のない押圧子8では、抜脱荷重の測定値に多少変動が見られ、拡開変形時の微小な偏心や急激な変形による影響が考えられる。この結果から、安定的な品質を維持する上では、凸部に傾斜が有る押圧子8′を用いることが有利であると言える。   In addition, in the pressing element 8 ′ having a slope in the convex portion, the measured value of the removal load is stable, whereas in the pressing element 8 without the inclination, the measured value of the removal load is somewhat varied, The effects of minute eccentricity and rapid deformation at the time of expansion deformation can be considered. From this result, in order to maintain stable quality, it can be said that it is advantageous to use a pressing element 8 ′ having an inclined protrusion.

さらに、図13に示すように、拡開部71cが車両の上下方向Zおよび水平方向Wを避けるように配置することによって、ブッシュ7のゴム特性への影響を最低限とすることが好ましい。図示例では、4箇所の拡開部71cが、上下方向Zおよび水平方向Wに対して約45度ずれて90度間隔に配置されている。   Furthermore, as shown in FIG. 13, it is preferable to minimize the influence on the rubber characteristics of the bush 7 by arranging the expanding portion 71c so as to avoid the vertical direction Z and the horizontal direction W of the vehicle. In the illustrated example, the four expanded portions 71c are arranged at 90 ° intervals with a shift of about 45 ° with respect to the vertical direction Z and the horizontal direction W.

以上、本発明の実施の形態について述べたが、本発明は上記実施形態に限定されるものではなく、本発明の技術的思想に基づいてさらに各種の変形および変更が可能である。   Although the embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments, and various modifications and changes can be made based on the technical idea of the present invention.

例えば、上記実施形態では、本発明のサスペンションアームを、マルチリンク式サスペンションのロアアームに実施する場合を示したが、ダブルウィッシュボーン式、トレーリングアーム式を始め、他の形式のサスペンションアームにも実施可能である。   For example, in the above-described embodiment, the case where the suspension arm of the present invention is implemented in the lower arm of a multi-link suspension is shown, but it is also implemented in other types of suspension arms such as a double wishbone type and a trailing arm type. Is possible.

本発明を自動車のリアサスペンションにおけるロアアームに実施した実施形態を示す側面図である。1 is a side view showing an embodiment in which the present invention is implemented in a lower arm in a rear suspension of an automobile. 本発明実施形態のロアアームを示す斜視図である。It is a perspective view which shows the lower arm of this invention embodiment. 図1のA−A断面図である。It is AA sectional drawing of FIG. 本発明実施形態のロアアームの製造工程を示す斜視図である。It is a perspective view which shows the manufacturing process of the lower arm of this invention embodiment. 本発明実施形態のロアアームの製造工程を示す斜視図である。It is a perspective view which shows the manufacturing process of the lower arm of this invention embodiment. 図4のB−B断面図である。It is BB sectional drawing of FIG. (a)は図4のC−C断面図、(b)は図5のD−D断面図、(c)はブッシュの断面図である。(A) is CC sectional drawing of FIG. 4, (b) is DD sectional drawing of FIG. 5, (c) is sectional drawing of a bush. ブッシュ外筒の拡開かしめ工程を示す断面図である。It is sectional drawing which shows the expansion process of a bush outer cylinder. (a)はブッシュ外筒の拡開かしめ加工を行なう押圧子の例を示す正面図、(b)は、その側面図である。(A) is a front view which shows the example of the presser which performs the expansion | swelling process of a bush outer cylinder, (b) is the side view. (a)はブッシュ外筒の拡開かしめ加工を行なう押圧子の他の例を示す正面図、(b)はその側面図である。(A) is a front view which shows the other example of the presser which performs the expansion process of a bush outer cylinder, (b) is the side view. 拡開かしめ加工を行なったブッシュを示す端面図である。It is an end view which shows the bush which performed the opening and closing process. ブッシュ外筒の嵌合公差と抜脱荷重との関係を示すグラフである。It is a graph which shows the relationship between the fitting tolerance of a bush outer cylinder, and a removal load. 本発明実施形態に係わるロアアーム基端部の取付け状況を示す側面図である。It is a side view which shows the attachment condition of the lower arm base end part concerning this invention embodiment.

符号の説明Explanation of symbols

1 ロアアーム
1A、1B 押出形材
2 アッパーアーム
3 車輪
4 ナックル
5 車体構造
6 コイルスプリング
7 ブッシュ
8、8′ 押圧子
10、20 貫通孔
11 基端部
12 先端部
13 中間部(コイルスプリング受け部)
14 上面部
15 下面部
16、17 側壁部
71 外筒
71c 拡開部
72 内筒
73 ゴム部
81、81′ 凸部
110、120 切欠部
111、112、121、122 両側部分
DESCRIPTION OF SYMBOLS 1 Lower arm 1A, 1B Extrusion member 2 Upper arm 3 Wheel 4 Knuckle 5 Car body structure 6 Coil spring 7 Bush 8, 8 'Presser 10, 20 Through-hole 11 Base end part 12 Tip part 13 Middle part (coil spring receiving part)
14 Upper surface portion 15 Lower surface portion 16, 17 Side wall portion 71 Outer tube 71c Expanded portion 72 Inner tube 73 Rubber portion 81, 81 ′ Convex portion 110, 120 Notch portion 111, 112, 121, 122 Both side portions

Claims (6)

上面部と下面部とが少なくとも2つの側壁部で連結され長手方向に一様な断面略四角形状をなす中空のアルミニウム合金製押出形材からの二次加工によって形成された車両用サスペンションアームであって、
前記押出形材の一端部が、その縁端から前記上面部および前記下面部の幅方向中央部に長手方向に延びる上下同形のスリット状の切欠部で分断され、その両側部分が、前記切欠部を変形代とした両側方からの曲げ加工で突き合わされて幅狭に構成されるとともに、該幅狭の両側部分で前記各側壁部を貫通する貫通孔に円筒状の連結部材が嵌挿され、かつ、前記連結部材の前記各貫通孔から側方に突出した両端部が拡開され、該拡開端部のかしめによって前記両側部分が一体に連結されており、前記一端部が、前記連結部材を介して車体構造側または車軸側に回動可能に連結されていることを特徴とする車両用サスペンションアーム。
A suspension arm for a vehicle formed by secondary processing from a hollow aluminum alloy extruded shape having an upper surface portion and a lower surface portion connected by at least two side wall portions and having a substantially rectangular cross section in the longitudinal direction. And
One end portion of the extruded shape member is divided by a slit-shaped notch portion having an upper and lower shape that extends in the longitudinal direction from the edge to the center portion in the width direction of the upper surface portion and the lower surface portion, and both side portions thereof are the notch portions. Is formed with a narrow width by being abutted by bending from both sides with a deformation margin, and a cylindrical connecting member is inserted into a through-hole penetrating each side wall portion at both narrow side portions, And the both ends which protruded from the said through-hole of the said connection member to the side are expanded, the said both side parts are integrally connected by the crimping of this said expansion end part, and the said one end part connects the said connection member. A suspension arm for a vehicle, wherein the suspension arm is pivotally connected to a vehicle body structure side or an axle side through a suspension.
前記連結部材の前記両端部が、周方向に所定のピッチ複数箇所にて拡開されていることを特徴とする請求項1に記載の車両用サスペンションアーム。 2. The vehicle suspension arm according to claim 1, wherein the both end portions of the connecting member are expanded at a plurality of locations at a predetermined pitch in the circumferential direction. 前記連結部材が、内筒と外筒とそれらの間に介在するゴム部とで構成されるブッシュであり、前記ブッシュの前記外筒が前記貫通孔に嵌挿され、かつ、前記外筒の両端部が拡開されており、前記押出形材の一端部が、前記ブッシュを介して車体構造側に揺動可能に枢支されていることを特徴とする請求項1または2に記載の車両用サスペンションアーム。   The connecting member is a bush composed of an inner cylinder, an outer cylinder, and a rubber portion interposed therebetween, and the outer cylinder of the bush is fitted into the through hole, and both ends of the outer cylinder 3. The vehicle according to claim 1, wherein a portion is expanded, and one end of the extruded shape member is pivotally supported on the vehicle body structure side via the bush. Suspension arm. 前記押出形材の前記上面部が、前記各側壁部との接続部を越えて幅方向に張出しており、前記押出形材の長手方向中間部にコイルスプリングの受け部が設けられていることを特徴とする請求項3に記載の車両用サスペンションアーム。   The upper surface portion of the extruded shape member extends in the width direction beyond the connection portion with each side wall portion, and a receiving portion of a coil spring is provided at a middle portion in the longitudinal direction of the extruded shape member. The vehicle suspension arm according to claim 3. 上面部と下面部とが少なくとも2つの側壁部で連結され長手方向に一様な断面略四角形状をなす中空のアルミニウム合金製押出形材を用いた車両用サスペンションアームの製造方法であって、
前記押出形材の一端部から、前記上面部および前記下面部の幅方向中央部を長手方向に上下同形のスリット状に切欠する工程と、
前記スリット状の切欠によって分断された前記押出形材一端部の両側部分を、両側方から曲げ加工して突き合わせる工程と、
前記押出形材一端部に前記各側壁部を貫通する貫通孔を穿設する工程と、
前記各側壁部の前記貫通孔に円筒状連結部材を嵌挿する工程と、
前記連結部材の前記各貫通孔から側方に突出した両端部を拡開してかしめ、前記両側部分を一体に連結する工程と、を含む、車両用サスペンションアームの製造方法。
A method for manufacturing a suspension arm for a vehicle using a hollow aluminum alloy extruded profile in which an upper surface portion and a lower surface portion are connected by at least two side wall portions and have a substantially rectangular cross section in the longitudinal direction,
From the one end portion of the extruded profile, a step of cutting the upper surface portion and the width direction center portion of the lower surface portion into a slit shape having an upper and lower shape in the longitudinal direction;
Bending both sides of the one end portion of the extruded profile divided by the slit-shaped notch, and abutting them from both sides; and
Drilling a through-hole penetrating each side wall at one end of the extruded profile;
Inserting a cylindrical connecting member into the through hole of each side wall; and
A method for manufacturing a suspension arm for a vehicle, comprising: expanding and caulking both end portions of the connecting member protruding from the respective through-holes and connecting the both side portions together.
前記両側部分を一体に連結する工程が、前記連結部材の前記両端部をその周方向に所定のピッチ複数箇所にて拡開してかしめることを含む、請求項5に記載の車両用サスペンションアームの製造方法。 The vehicle suspension according to claim 5, wherein the step of integrally connecting the both side portions includes expanding and crimping the both end portions of the connecting member at a predetermined pitch in the circumferential direction at a predetermined pitch. The manufacturing method of an arm.
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