JP6437758B2 - 等速自在継手の接合タイプ外側継手部材の検査装置 - Google Patents
等速自在継手の接合タイプ外側継手部材の検査装置 Download PDFInfo
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- JP6437758B2 JP6437758B2 JP2014164108A JP2014164108A JP6437758B2 JP 6437758 B2 JP6437758 B2 JP 6437758B2 JP 2014164108 A JP2014164108 A JP 2014164108A JP 2014164108 A JP2014164108 A JP 2014164108A JP 6437758 B2 JP6437758 B2 JP 6437758B2
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- G01N29/043—Analysing solids in the interior, e.g. by shear waves
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
- B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to investigating the properties, e.g. the weldability, of materials
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- F16D1/00—Couplings for rigidly connecting two coaxial shafts or other movable machine elements
- F16D1/02—Couplings for rigidly connecting two coaxial shafts or other movable machine elements for connecting two abutting shafts or the like
- F16D1/027—Couplings for rigidly connecting two coaxial shafts or other movable machine elements for connecting two abutting shafts or the like non-disconnectable, e.g. involving gluing, welding or the like
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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- F16D3/226—Universal joints in which flexibility is produced by means of pivots or sliding or rolling connecting parts one coupling part entering a sleeve of the other coupling part and connected thereto by sliding or rolling members the rolling members being balls, rollers, or the like, guided in grooves or sockets in both coupling parts the rolling members being guided in grooves in both coupling parts the groove centre-lines in each coupling part lying on a cylinder co-axial with the respective coupling part
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- Welding Or Cutting Using Electron Beams (AREA)
- Shafts, Cranks, Connecting Bars, And Related Bearings (AREA)
- Investigating Or Analyzing Materials By The Use Of Ultrasonic Waves (AREA)
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Description
なお、固定式等速自在継手としてアンダーカットフリー型等速自在継手を用いる場合もある。
外側継手部材11は、図2(a)に示すように、カップ部12と、軸部(ロングステム部)13とからなる。この外側継手部材11は、カップ部材12aと軸部材13aを突合せ溶接により接合して製造するが、製造工程については後に詳しく述べる。
くぼみ52の深さの上限は、くぼみを鍛造の過程で成形する場合、鍛造で成形できる限界値(目安)×1.5mm程度とする。くぼみ52が深すぎると、鍛造負荷が高まり、金型寿命が低下し、加工コストが増大する。切削加工により形成する場合でも、くぼみ52が深すぎると加工時間が長くなり、材料歩留まりも悪くなる。
一方、軸部材13aは、バー材切断工程S1sと、旋削工程S2sと、スプライン加工工程S3sとからなる製造工程により製造される。
まず、カップ部材12aの製造工程について述べる。
鍛造重量に基づいてバー材(丸棒)を所定長さに切断し、柱状のビレットを製作する。
ビレットに鍛造加工を施すことにより、カップ部材12aの素形材として、筒部と底部と凸部を一体成形する。
上記素形材のトラック溝30及び筒状円筒面42をしごき加工して、カップ部材12aの筒部の内周を仕上げる。
しごき加工後の素形材に、外周面、ブーツ取付溝32、止め輪溝33などと接合用端面50を旋削加工する。旋削工程S4cを経た中間部品としてのカップ部材12aに品番を付与して管理する。
軸部全長に基づいてバー材を所定長さに切断し、柱状のビレットを製作する。その後、軸部材13aの形状に応じて、ビレットをアプセット鍛造により概略形状に鍛造加工する場合もある。
ビレットの外周面(軸受装着面14、止め輪溝15、スプライン下径、端面など)とカップ部材12a側端部の接合用端面51を旋削加工する。
旋削加工後の軸部材にスプラインを転造加工してスプライン軸を形成する。ただし、スプラインの加工は転造加工に限られるものではなく、適宜プレス加工等に置き換えることもできる。スプライン加工を経た中間部品としての軸部材13aに品番を付与して管理する。
カップ部材12aの接合用端面50と軸部材13aの接合用端面51を突き合わせて溶接する。この溶接工程については後に詳しく述べる。
カップ部材12aと軸部材13aの溶接部49を超音波探傷により検査する。この超音波探傷工程についても後に詳しく述べる。
溶接後のカップ部12の少なくともトラック溝30及び内周面42並びに軸部材13の外周の必要範囲に高周波焼入れ焼戻しの熱処理を行う。溶接部49は熱処理を施さない。熱処理により、カップ部12のトラック溝30や内周面42はHRC58〜62程度の硬化層が形成される。また、軸部13の外周の所定範囲にHRC50〜62程度の硬化層が形成される。
熱処理後、軸部材13の軸受装着面14等を研削加工して仕上げる。これにより、外側継手部材11が完成する。
炭素量0.4〜0.6%のカップ部材12aと、炭素量0.3〜0.55%の軸部材13aを用いて、溶接装置100で、ケース108内の密閉空間111の圧力を6.7Pa以下に設定して溶接した。溶接後の急冷を防止して溶接部の硬さが高くなりすぎないようにするため、カップ部材12a、軸部材13aの接合用端面50、51を含む周辺が300〜650℃になるよう電子ビームによる予熱で均熱化した後、電子ビーム溶接を行った。その結果、予熱時間は接合用端面の内径側にくぼみを設けない場合に比べて約1/2以下に短縮でき、必要強度を満足する良好な溶接部を得ることができた。
このように、カップ部材12aの接合用端面50に突出面50aを設けたことにより、反射エコーのエコー高さが低くなり、検査の精度を高めることができる。
突出面50aの寸法は、図17(a)に示すように、突出面50aの半径方向の幅をS〔S=(E−D)/2〕とし、接合用端面51の内径Eからの裏波ビード49aの高さをQとしたとき、S≧Qの関係とする。この関係にあれば、反射エコーの高さを明確に区別することができ、溶接良品、不良品を精度よく判定することができる。このS≧Qの関係を維持すれば、突出面50aの寸法は適宜設定することができる。なお、接合用端面51の内径Eは、くぼみ52(の内径部53)の内径でもある。
図示するように、カップ部材は一つのジョイントサイズで共用化され、たとえば品番C001を付与して管理される。これに対して、軸部材は、車種ごとに種々の軸部仕様を備え、たとえば品番S001、S002、〜S(n)を付与して管理される。そして、たとえば品番C001のカップ部材と品番S001の軸部材を組み合わせて溶接すると、品番A001の外側継手部材を製作することができる。
この第二の例は、すでに述べた第一の例におけるカップ部材の接合用端面に設けた突出面の形態が異なる。その他の構成は第一の例と同じであるため、第一の例と同じ機能を有する部位には下付き数字のみ変えた同一の符号を付して、重複した説明を省略する。
この第二の例は、図3の熱処理工程S7中のカップ部材の熱処理工程を溶接工程S6の前に組み入れて熱処理工程S5cとし、カップ部材については完成品として準備するようにしたものである。この点を除き、製造方法の第一の例についてすでに述べた事項すなわち、各工程の概要、カップ部材及び軸部材の主な加工工程における状態、カップ部材の共用化、溶接方法、超音波探傷、品種統合や外側継手部材の構成などは製造方法の第二の例にもあてはまる。
ここでは、外側継手部材の第一の例と同様の機能を有する箇所には同一の符号を付して要点のみを説明する。
カップ部材12a2は、筒状部12a12と底部12a22からなる一体成形品で、筒状部12a12の内周にはトラック溝130と内周面131が形成されている。底部12a22には短軸部12a32が形成されている。カップ部材12a2の開口側の外周にはブーツ取付溝32が形成されている。
軸部材13aは、カップ部材12a2側の外周に軸受装着面14及び止め輪溝15が形成され、カップ部材12a2とは反対側の端部にスプライン軸Spが形成されている。
たとえば、最大作動角の異なる仕様により一つのジョイントサイズで複数の種類(複数品番)のカップ部材を設定し、これらのカップ部材の上記接合用端面の外径を同一寸法にすることや、上記突出面を同一に設定することも含まれる。
また、これに加えて、たとえば、継手機能や製造現場の実情、生産性等を考慮して、カップ部材を熱処理前の中間部品と熱処理を施した完成部品の複数形態で管理するために、一つのジョイントサイズで複数の種類(複数品番)のカップ部材を設定し、これらのカップ部材の上記接合用端面の外径を同一寸法にすることや、上記突出面を同一に設定することも含まれる。
たとえば、インボード側では、トリポード型等速自在継手とダブルオフセット型等速自在継手の上記接合用端面の外径を同一寸法にすることや、上記突出面を同一に設定することも含まれる。また、アウトボード側では、ツェッパ型等速自在継手とアンダーカットフリー型等速自在継手の上記接合用端面の外径を同一寸法にすることや、上記突出面を同一に設定することも含まれる。さらに、インボード側とアウトボード側の等速自在継手の上記接合用端面の外径を同一寸法にすることや、上記突出面を同一に設定することも可能である。
11、111、112 外側継手部材
12、121、122 カップ部
12a、12a1、12a2 カップ部材
12a1、12a11、12a12 筒状部
12a2、12a21、12a22 底部
12a3、12a31、12a32 短軸部
13 軸部(ロングステム部)
13a、13b 軸部材
16 内側継手部材
41 トルク伝達要素(ボール)
49 溶接部
49a 裏波ビード
80 検査装置
82 冷却水槽
84 水切り装置
86 ダイヤルゲージ(接触式変位計)
88 レーザ変位計
90 ロボットハンド
100 溶接装置
120 超音波探傷装置
I 冷却部
II 水切り部
III 表面検査部
IV 内部検査部
Claims (4)
- トルク伝達要素が転動するトラック溝を内周に形成した有底筒状のカップ部と、このカップ部の底から軸方向に延びる軸部とからなり、軸部がサポートベアリングによって支持され、前記カップ部を形成するカップ部材と前記軸部を形成する軸部材とを溶融溶接した等速自在継手の外側継手部材を検査するための装置であって、
外側継手部材の表面に現れた溶接に起因する欠陥を検出するための検査を行う表面検査部と、溶接部の内部欠陥の検査をするための内部検査部と、上記検査の検査結果を記録する記録部を具備し、
前記表面検査部が、溶接後の外側継手部材の振れを測定する接触式ゲージと、前記溶接部のビード表面の全周にわたりピットの検出を行うレーザ変位計とを有し、
前記内部検査部が超音波探傷により内部欠陥を検査することを特徴とする等速自在継手の接合タイプ外側継手部材の検査装置。 - 前記内部検査部は、超音波探傷により、溶込み不良、ブローホール、溶接割れの少なくとも一つを検出することを特徴とする請求項1に記載の等速自在継手の接合タイプ外側継手部材の検査装置。
- 前記記録部は、上記検査の検査結果をワークごとにその品番と対応づけて記録することを特徴とする請求項1または2に記載した等速自在継手の接合タイプ外側継手部材の検査装置。
- 前記表面検査部に、冷却水で冷却した前記外側継手部材が送られる請求項1〜3何れか1項に記載した等速自在継手の接合タイプ外側継手部材の検査装置。
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