KR101855109B1 - A Manufacturing Method of Wheel Support Member for Vehicle - Google Patents

Abstract

The present invention provides a method to manufacture a wheel support body for a vehicle, comprising: a mold manufacturing step of making a mold including upper and lower molds; a seam member making step of making a seam member formed of a second material; a mold coupling step of placing the seam member made in the seam member making step between the upper and lower molds, and coupling the upper and lower molds; a molten metal injection step of injecting molten metal melting a first material through a molten metal injection hole formed in the upper mold; a molded product removing step of separating the upper and lower molds to remove a molded product formed of the solidified molten metal; and a post-treatment step of removing a protrusion part of the seam member protruding out of the molded product through post treatment. Accordingly, provided are effects capable of maintaining sufficient strength and pursuing lightweight of a wheel support body of a vehicle at the same time.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a wheel support for a vehicle, and more particularly, to a method for manufacturing a wheel support for a vehicle having a seam member of different materials and having excellent rigidity.

2. Description of the Related Art Generally, a suspension of a vehicle connects an axle and a vehicle body, thereby preventing a vibration or an impact from a road surface from being directly transmitted to the vehicle body during traveling of the vehicle, thereby improving ride comfort.

These suspension devices are classified into a single-axle suspension system and an independent suspension system depending on the type of axle, and an independent suspension system is generally used for a passenger car that emphasizes ride comfort and maneuverability.

The configuration of the independent suspension device is shown in Korean Laid-Open Publication No. 10-2015-0066110.

The wheel is mounted on a vehicle wheel support (carrier or knuckle), which is connected to the cross member through adjacent structures such as an upper arm, a lower arm, an assist arm, and the like, .

Here, the vehicle wheel support used for the suspension device of the front wheel of the vehicle is referred to as a knuckle (or steering knuckle), and the vehicle wheel support used for the suspension device of the rear wheel of the vehicle is referred to as a carrier.

Such a wheel support for a vehicle is mainly manufactured by casting, and a spheroidal graphite cast iron or an aluminum material is used as a material thereof.

However, since the vehicle wheel support made of the spheroidal graphite cast iron has a brittle material characteristic, it can be easily broken if a certain range of deformation occurs due to the impact load, so that there is a problem that the weight of the product is limited in order to have sufficient rigidity .

In addition, in order to reduce the weight of the product, the vehicle wheel support made of aluminum material is light compared to the wheel support made of spheroidal graphite cast iron, but it has to be bulky in order to have a strength corresponding thereto. As a result, And there is a problem that it is difficult to produce a certain quality product because of bubble generation problem.

Korean Patent Publication No. 10-2007-0040233 (published on April 16, 2007)

SUMMARY OF THE INVENTION It is an object of the present invention to provide a vehicle wheel support having sufficient rigidity and reduced weight, and a method of manufacturing the same.

A method for manufacturing a wheel support for a vehicle according to the present invention comprises the steps of: forming a mold for manufacturing a mold including upper and lower molds; producing a seam member made of a second material; A mold coupling step of placing the core member manufactured in the step of manufacturing the core member between the upper and lower molds and coupling the upper and lower molds; A molten metal injection step of injecting a molten metal melting the first material through a molten metal injection port formed in the upper mold; Separating the upper mold and the lower mold to take out a molded product formed by hardening the molten metal; And a post-processing step of removing a protruding portion of the seam member protruding outside the mold through a post-process.

In the method of manufacturing a wheel support for a vehicle according to the present invention, the step of fabricating the seam member may include the steps of: forming a net structure having a planar net structure made of wires; And a net structure bending step of bending the net-shaped plan structure formed in the net structure forming step so as to correspond to the shape of the vehicle wheel support.

In the method for manufacturing a vehicle wheel support according to the present invention, the melting point of the second material may be higher than that of the first material.

In the method for manufacturing a vehicle wheel support according to the present invention, the elastic modulus and the yield stress of the second material may be larger than those of the first material.

In the method for manufacturing a vehicle wheel support according to the present invention, at least one of the upper and lower molds may be provided with a seam member fixing groove into which an outer portion of the seam member is inserted and fixed.

According to the method for manufacturing a vehicle wheel support according to the present invention, the vehicle wheel support has a seam member made of different materials and has sufficient rigidity and can be lightweight.

1 is a perspective view of a vehicle wheel support according to an embodiment of the present invention;
2 is a transmission perspective view of a vehicle wheel support according to an embodiment of the present invention.
3 is a perspective view for explaining a structure of a seam member;
4 is a reference view showing various forms of a mesh of a seam member;
5 is a reference view showing a form in which wires cross in a seam member;
6 and 7 are views for explaining a method of testing rigidity of a vehicle wheel support according to an embodiment of the present invention and the results thereof.
8 is a flowchart of a method of manufacturing a vehicle wheel support according to an embodiment of the present invention.
9 is a conceptual view showing a method of manufacturing a wheel support for a vehicle according to an embodiment of the present invention.
10 is a plan view showing a seam member coupled to a top or bottom.
11 is a cross-sectional view taken along line AA of Fig.
12 is a sectional view different from BB of Fig. 7;

Hereinafter, specific embodiments of the present invention will be described in detail with reference to the drawings. It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the inventive concept as defined by the appended claims. Other embodiments falling within the scope of the inventive concept may be easily suggested, but are also included within the scope of the invention.

In the following description, the same reference numerals are used to designate the same components in the same reference numerals in the drawings.

FIG. 1 is a perspective view of a vehicle wheel support 100 according to an embodiment of the present invention, and FIG. 2 is a perspective view of a vehicle wheel support 100 according to an embodiment of the present invention.

Although the vehicle wheel support 100 is a knuckle in the following description, the vehicle wheel support 100 according to the present invention is not limited to a knuckle, carrier. < / RTI >

1 and 2, a vehicle wheel support 100 according to an embodiment of the present invention includes a hub bearing coupling part 110 and at least one connection part 120, 130, 140 and 150, A seam member 190 made of a second material may be embedded in a body made of a first material.

The hub bearing coupling part 110 may include a hub bearing mounting hole 111 on which a hub bearing (not shown) is mounted.

The connection portions 120, 130, 140 and 150 may extend from the hub bearing coupling portion 110 and may be connected to adjacent structures.

At this time, the connection portions 120, 130, 140 and 150 include a strut portion 120 to which a knuckle bracket (not shown) is connected, a brake caliper connecting portion 130 to which a brake caliper (not shown) A tie rod connecting portion 140 to which a lower arm (not shown) is connected, or a lower arm connecting portion 150 to which a lower arm (not shown) is connected.

The strut part 120 may extend from the upper part of the hub bearing coupling part 110 in the form of an arm.

The brake caliper connecting portion 130 may be provided on one side of the hub bearing coupling portion 110 and the tie rod coupling portion 140 may be provided on the other side of the hub bearing coupling portion 110 .

The lower arm coupling part 150 may be provided at a lower portion of the hub bearing coupling part 110.

Referring to FIG. 2, the vehicle wheel support 100 according to an embodiment of the present invention may include a seam member 190 formed of a heterogeneous material in a body.

In other words, the vehicle wheel support 100 according to an embodiment of the present invention includes a body 180 made of a first material, a seam member 190 made of a second material, .

At this time, the body 180 may form an outer appearance of the vehicle wheel support 100.

That is, the body 180 has an outer appearance of the hub bearing coupling part 110, the strut part 120, the brake caliper connecting part 130, the tie rod connecting part 140 and the lower arm connecting part 150 .

Here, the first material forming the body 180 may be spheroidal graphite iron (FCD) or aluminum.

Meanwhile, the second material forming the seam member 190 may have a higher melting point than the first material.

In this way, the vehicle wheel support 100 according to an embodiment of the present invention can be manufactured through insert casting, in which the seam member 190 is inserted into the mold and the molten metal of the first material is injected into the mold. ) Can be produced.

If the melting point of the second material is lower than the melting point of the first material, the seam member 190 melts in the casting process described above, and the shape can not be maintained.

The second material may have a higher elastic modulus and yield stress than the first material.

As described above, since the body 180 made of the first material has a seam member made of a second material having a relatively large elastic modulus and yield stress, the rigidity of the vehicle wheel support 100 can be made large Can be improved.

More specifically, when the first material is spheroidal graphite cast iron, a seam member 190 made of a second material having a higher elastic modulus and a higher ductility than the spheroidal graphite cast iron is built in, It is possible to manufacture the vehicle wheel support 100 having the same strength but with a reduced weight.

In addition, when the first material is made of aluminum, the seam member 190 made of the second material having a higher elastic modulus and yield stress than that of aluminum is incorporated, thereby improving the strength, It is possible to solve the interference problem between the parts and to manufacture the vehicle wheel support 100 which is light in weight.

In addition, since the seam member 190 is embedded therein, it is possible to solve the problem of pores generated inside the casting process.

3 is a perspective view illustrating the structure of the seam member 190. As shown in FIG.

Referring to FIGS. 2 and 3, the seam member 190 may be in the form of a mesh structure of wires 193.

At this time, the seam member 190 may be bent to correspond to the shape of the body portion 180.

2, the seam member 190 includes a hub bearing engagement corresponding portion 191 corresponding to the hub bearing coupling portion 110, and a hub bearing coupling corresponding portion 191 corresponding to the hub bearing coupling portion 110, And may include corresponding connection counterparts 192.

At this time, the connection corresponding portion 192 is connected to the connection portions 120, 130, 140 and 150, that is, the strut portion 120, the brake caliper connection portion 130, the tie rod connection portion 140, Respectively. As shown in FIG.

Meanwhile, the seam member 190 may be a net structure having a mesh 194 having a predetermined shape.

4 is a reference view showing various forms of the mesh 194 of the seam member 190. As shown in FIG.

Referring to FIG. 4, the meshes 194 of the seam member 190 are triangular (FIG. 3A), square (FIG. 3B), or hexagonal (FIG. Lt; / RTI >

Meanwhile, the wire 193 may have various cross-sections such as circular, square, and hexagonal cross-sections.

5 is a reference view showing a state in which the wire 193 intersects the seam member 190. As shown in FIG.

5, the shape of the wire 193 in the seam member 190 is such that two intersecting wires 193 overlap each other, as shown in FIG. 5 (a) As shown in FIG. 5 (b), when one of the two wires 193 'and 193' 'intersecting each other runs over the other wire 193' ' Lt; / RTI >

6 and 7 are views for explaining a method of testing the stiffness of the vehicle wheel support 100 according to an embodiment of the present invention and the results thereof.

6A, the X, Y, and Z displacements of the hub bearing coupling portion 110 are constrained and a load of F1 is applied to the street portion 120 in the Y direction.

6 (b) shows the result of the stress analysis for the test of FIG. 6 (a).

A conventional vehicle wheel support formed of only a first material having an elastic modulus of 73,500 MPa, a Poisson's ratio of 0.33, and a yield strength of 250.2 MPa, and a body portion 180 formed of the first material, and having an elastic modulus of 117,506 MPa, a Poisson's ratio of 0.30, A load F1 of 65,000 N was applied to the wheel support 100 for a vehicle according to an embodiment of the present invention in which a seam member 190 was formed of a second material of 400 MPa.

At this time, the rigidity of the conventional vehicle wheel support was measured to be 157,461 N / mm, and the rigidity of the vehicle wheel support 100 according to one embodiment of the present invention was measured to be 199,357 N / mm.

As a result, it can be seen that the rigidity of the vehicle wheel support 100 according to an embodiment of the present invention is improved by 27% as compared with the rigidity of the conventional vehicle wheel support.

Referring to FIG. 7A, the X, Y, and Z displacements of the hub bearing coupling portion 110 are constrained and a load of F2 is applied to the tie rod coupling portion 140 in the Y direction.

Fig. 7 (b) shows the result of the stress analysis for the test of Fig. 7 (a).

Here, a conventional vehicle wheel support formed of only a first material having an elastic modulus of 73,500 MPa, a Poisson's ratio of 0.33, and a yield strength of 250.2 MPa, and a body portion 180 formed of the first material and having elastic modulus of 117,506 MPa, Poisson's ratio of 0.30 , And a load (F2) of 15,000 N was applied to the vehicle wheel support 100 according to an embodiment of the present invention in which a seam member 190 was formed of a second material having a yield strength of 400 MPa.

At this time, the rigidity of the conventional vehicle wheel support was measured to be 3,842 N / mm, and the rigidity of the vehicle wheel support 100 according to an embodiment of the present invention was measured to be 3,949 N / mm.

As a result, it can be seen that the rigidity of the vehicle wheel support 100 according to an embodiment of the present invention is improved by 2.8% as compared with the rigidity of the conventional vehicle wheel support.

As described above, the vehicle wheel support 100 according to an embodiment of the present invention has significantly improved rigidity compared to a conventional vehicle wheel support, though it varies depending on the size and direction of the load.

Hereinafter, a manufacturing method (S100) of a wheel support for a vehicle according to an embodiment of the present invention will be described in detail with reference to the drawings.

FIG. 8 is a flowchart of a manufacturing method (S100) of a wheel support for a vehicle according to an embodiment of the present invention, and FIG. 9 is a conceptual diagram illustrating a manufacturing method (S100) of a wheel support for a vehicle according to an embodiment of the present invention.

8 and 9, a method (S100) of manufacturing a wheel support for a vehicle according to an embodiment of the present invention includes a mold making step (S110, FIG. 9A), a seam member making step (Fig. 9 (b)), the mold joining step (S130, Fig. 9 (c)), the molten metal injection step (S140, , And a post-processing step (S160, Figure 9 (f)).

The mold making step S110 may be a step of manufacturing the mold 200 having the inner surface formed to correspond to the outer shape of the vehicle wheel support 100 as shown in Fig. 9 (a).

At this time, the mold 200 may include a top mold 210 forming the upper part and a lower mold 220 forming the bottom part.

Here, the mold 200 may include a cavity 230 formed by coupling the upper mold 210 and the lower mold 220.

The cavity 230 may be formed in a shape corresponding to the shape of the vehicle wheel support 100 so that the shape of the vehicle wheel support 100 is formed by the casting method by injecting the molten metal into the cavity 230 .

The seam member manufacturing step S120 may be a step of fabricating a seam member 190 in the form of a net composed of a wire 193.

In the meantime, the seam member manufacturing step S120 may include a net structure forming step S121 for forming a plan net structure made of the wire 193 and a net structure forming step S122 for forming the net structure corresponding to the shape of the vehicle wheel support 100 And a net structure bending step S122 for bending the net-like net structure formed in step S121.

Meanwhile, the seam member 190 may be formed of a second material having a higher melting point than the first material, which is a material of the molten metal injected into the mold 200.

The second material may have a higher elastic modulus and yield stress than the first material.

This makes it possible to increase the rigidity of the manufactured vehicle wheel support 100 and at the same time to pursue weight reduction.

The mold coupling step S130 may be performed by positioning the seam member 190 manufactured in the seam member manufacturing step between the upper mold 210 and the lower mold 220, And the lower mold 220 may be combined.

At this time, in order to fix the seam member 190 between the upper and lower molds 210 and 220, at least one of the upper and lower molds 210 and 220 may have a seam member The fixing grooves 211 and 221 may be formed.

10 is a plan view showing that a seam member 190 is coupled to the upper mold 210 or the lower mold 220. FIG. 11 is a sectional view taken along AA of FIG. 10, and FIG. Sectional view.

10 to 12, the seam member fixing grooves 211 and 221 are formed at a portion where the upper mold 210 and the lower mold 220 contact the upper mold 210 and the lower mold 220, May be formed to correspond to the shape of the outer portion of the seam member (190).

The seam member 190 may be fixed between the upper mold 210 and the lower mold 220 by the engagement of the upper mold 210 and the lower mold 220. [

That is, the seam member is fixed to the inside of the cavity 230 so that the seam member does not contact the upper surface of the upper mold 210 or the upper surface of the lower mold 220 forming the cavity 230, The seam member 190 may be disposed at a suitable position in the interior of the vehicle wheel support 100.

The step of injecting the molten metal (S140) may be a step of injecting a molten metal of a first material into the mold 200.

At this time, a molten metal injection port 212 may be formed in the upper mold 210 to inject molten metal.

Meanwhile, the molten metal can be solidified in the mold 200, and the outer shape of the vehicle wheel support 100 can be formed through the solidification.

Here, the molten metal may be one obtained by melting spheroidal graphite cast iron or aluminum as the first material.

The mold removing step S150 is a step of separating the upper mold 210 and the lower mold 220 after the molten metal injected in the molten metal injecting step S140 is solidified to take out the molding formed by solidifying the molten metal .

The post-processing step S160 may be a step of removing the protruding portion 190 'of the seam member 190 protruding outside the molded article taken out in the molded article taking-out step S150.

As described above, according to the wheel support 100 for a vehicle and the method for manufacturing the same (S100) according to the present invention, it is possible to provide a wheel support 100 for a vehicle, which has a higher melting point and a higher elastic modulus and yield stress than the first material, The present invention provides a vehicle wheel support 100 in which a seam member made of two materials is formed in an inner shape and a manufacturing method S100 of the same to maintain sufficient rigidity and weight reduction.

While the invention has been shown and described with reference to certain embodiments thereof, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention as defined in the appended claims. It will be obvious to those of ordinary skill in the art.

100: A vehicle wheel support according to an embodiment of the present invention
110: Hub bearing fastening part 111: Hub bearing mounting hole
120, 130, 140, 150: connection part 180: body
190: seam member 193: wire
194: mesh 200: mold
210: upper mold 220: lower mold
211, 21: seam member fixing groove 212:
S100: A method for manufacturing a vehicle wheel support according to an embodiment of the present invention
S110: Mold making step S120: Seam member making step
S130: mold coupling step S140: molten metal injection step
S150: Molded article taking-out step S160: Post-molding step

Claims (5)

A method of manufacturing a vehicular wheel support including a hub bearing fastening portion formed with a hub bearing mounting hole and at least one connecting portion extending from the hub bearing fastening portion and connected to an adjacent structure,
A mold making step for producing a mold including upper mold and lower mold:
A seam member manufacturing step of manufacturing a seam member formed of a second material;
A mold coupling step of placing the core member manufactured in the step of manufacturing the core member between the upper and lower molds and coupling the upper and lower molds;
A molten metal melting the first material is injected through the molten metal injection port formed in the upper mold, and the molten metal is injected through the molten metal injection port formed in the upper mold to form a strut portion, a tie rod connecting portion, and a lower arm connecting portion extending from the hub bearing fastening portion and the hub bearing fastening portion, A step of injecting molten metal to form a molten metal;
Separating the upper mold and the lower mold to take out a molded product formed by hardening the molten metal; And
And a post-processing step of removing the protruding portion of the seam member protruding outside the mold through a post-process,
The step of fabricating the seam member comprises:
Forming a net structure which forms a planar net structure made of wires and which provides connection corresponding parts corresponding to the hub bearing fastening corresponding parts corresponding to the hub bearing fastening parts and the connecting part composed of the strut part, the tie rod connecting part and the lower arm connecting part step; And
And a net structure bending step of bending a net-like net structure formed in the net structure forming step so as to correspond to the shape of the wheel support of the vehicle,
The hub bearing fastening corresponding portion is formed to surround the hub bearing fastening portion and is connected to the connection corresponding portion,
The melting point of the second material is higher than that of the first material,
The elastic modulus and the yield stress of the second material are larger than those of the first material,
Wherein at least one of the upper and lower seams has a seam member fixing groove into which an outer portion of the seam member is inserted and fixed,
Wherein the step of joining the upper and lower seam members to the upper and lower seam members in the step of assembling the seam member comprises the step of joining the upper and lower seam members to each other so that the seam member can be embedded in the vehicle wheel support And a step of inserting and fixing an outer portion of the seam member into the seam member fixing groove to prevent the seam member from contacting the upper surface of the upper mold or the lower mold forming the cavity Wherein the wheel support is formed of a resin. delete delete delete delete

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