US20100037976A1 - Seamless steel pipe, hollow spring utilizing seamless steel pipe, and process for manufacturing the same - Google Patents

Seamless steel pipe, hollow spring utilizing seamless steel pipe, and process for manufacturing the same Download PDF

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Publication number
US20100037976A1
US20100037976A1 US12/530,709 US53070907A US2010037976A1 US 20100037976 A1 US20100037976 A1 US 20100037976A1 US 53070907 A US53070907 A US 53070907A US 2010037976 A1 US2010037976 A1 US 2010037976A1
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United States
Prior art keywords
steel pipe
seamless steel
hollow
spring
seamless
Prior art date
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Abandoned
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US12/530,709
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English (en)
Inventor
Kotaro Toyotake
Koji Iwaya
Tomoyuki Minami
Noritoshi Takamura
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
NHK Spring Co Ltd
Shinko Metal Products Co Ltd
Shinko Products Co Ltd
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NHK Spring Co Ltd
Shinko Products Co Ltd
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Application filed by NHK Spring Co Ltd, Shinko Products Co Ltd filed Critical NHK Spring Co Ltd
Assigned to NHK SPRING CO., LTD., SHINKO METAL PRODUCTS CO., LTD. reassignment NHK SPRING CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: IWAYA, KOJI, MINAMI, TOMOYUKI, TAKAMURA, NORITOSHI, TOYOTAKE, KOTARO
Publication of US20100037976A1 publication Critical patent/US20100037976A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B19/00—Tube-rolling by rollers arranged outside the work and having their axes not perpendicular to the axis of the work
    • B21B19/02—Tube-rolling by rollers arranged outside the work and having their axes not perpendicular to the axis of the work the axes of the rollers being arranged essentially diagonally to the axis of the work, e.g. "cross" tube-rolling ; Diescher mills, Stiefel disc piercers or Stiefel rotary piercers
    • B21B19/04—Rolling basic material of solid, i.e. non-hollow, structure; Piercing, e.g. rotary piercing mills
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
    • B21B1/42—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for step-by-step or planetary rolling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B21/00—Pilgrim-step tube-rolling, i.e. pilger mills
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C1/00—Manufacture of metal sheets, metal wire, metal rods, metal tubes by drawing
    • B21C1/16—Metal drawing by machines or apparatus in which the drawing action is effected by other means than drums, e.g. by a longitudinally-moved carriage pulling or pushing the work or stock for making metal sheets, bars, or tubes
    • B21C1/22—Metal drawing by machines or apparatus in which the drawing action is effected by other means than drums, e.g. by a longitudinally-moved carriage pulling or pushing the work or stock for making metal sheets, bars, or tubes specially adapted for making tubular articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/007—Hydrostatic extrusion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/02—Making uncoated products
    • B21C23/04—Making uncoated products by direct extrusion
    • B21C23/08—Making wire, bars, tubes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/02—Making uncoated products
    • B21C23/04—Making uncoated products by direct extrusion
    • B21C23/08—Making wire, bars, tubes
    • B21C23/085—Making tubes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21F—WORKING OR PROCESSING OF METAL WIRE
    • B21F3/00—Coiling wire into particular forms
    • B21F3/02—Coiling wire into particular forms helically
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/08—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for tubular bodies or pipes
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/04—Ferrous alloys, e.g. steel alloys containing manganese
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/34—Ferrous alloys, e.g. steel alloys containing chromium with more than 1.5% by weight of silicon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/46—Ferrous alloys, e.g. steel alloys containing chromium with nickel with vanadium
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16F—SPRINGS; SHOCK-ABSORBERS; MEANS FOR DAMPING VIBRATION
    • F16F1/00—Springs
    • F16F1/02—Springs made of steel or other material having low internal friction; Wound, torsion, leaf, cup, ring or the like springs, the material of the spring not being relevant
    • F16F1/04—Wound springs
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16F—SPRINGS; SHOCK-ABSORBERS; MEANS FOR DAMPING VIBRATION
    • F16F1/00—Springs
    • F16F1/02—Springs made of steel or other material having low internal friction; Wound, torsion, leaf, cup, ring or the like springs, the material of the spring not being relevant
    • F16F1/04—Wound springs
    • F16F1/042—Wound springs characterised by the cross-section of the wire
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16F—SPRINGS; SHOCK-ABSORBERS; MEANS FOR DAMPING VIBRATION
    • F16F1/00—Springs
    • F16F1/02—Springs made of steel or other material having low internal friction; Wound, torsion, leaf, cup, ring or the like springs, the material of the spring not being relevant
    • F16F1/04—Wound springs
    • F16F1/06—Wound springs with turns lying in cylindrical surfaces
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16F—SPRINGS; SHOCK-ABSORBERS; MEANS FOR DAMPING VIBRATION
    • F16F1/00—Springs
    • F16F1/02—Springs made of steel or other material having low internal friction; Wound, torsion, leaf, cup, ring or the like springs, the material of the spring not being relevant
    • F16F1/18—Leaf springs
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L9/00—Rigid pipes
    • F16L9/02—Rigid pipes of metal

Definitions

  • the present invention relates to a cylindrical seamless steel pipe, to be used as a material for coiled spring and the like, and a method for producing the same.
  • Major techniques for improving existing engines include “improvement of combustion method” and “energy-saving of power source by weight reduction”.
  • improvements of combustion method and “energy-saving of power source by weight reduction”.
  • automobile companies are engaged in developments of immediate weight reduction of whole car body.
  • Patent Document 1 discloses a method for producing steel pipe having no seam (which corresponds to “seamless steel pipe” of the present invention) for springs in which a spring steel material is heated and subjected to Mannesmann-piercing, and then to mandrel mill rolling to thereby obtain a hollow raw pipe, which is then subjected to finish rolling.
  • Patent Document 1 Japanese unexamined patent application laid-open specification, No. H1-247532
  • a section reduction per drawing should be considerably low as compared with general mild steel and the like, such as 20% (which specifically means that a pipe diameter of 100 mm 2 becomes 80 mm 2 ). Therefore, in the production method according to the above-mentioned patent document, there arises a problem that production efficiency becomes extremely poor.
  • decarburization and rolling patterns may occur due to repeated hot processing, and there arises a necessity to peel (grind) an outer periphery surface and an inner periphery surface of the seamless steel pipe. Grinding may result in generation of flaws, especially in the inner periphery surface of the seamless steel pipe.
  • the seamless steel pipe is produced by Mannesmann-piercing, and when a material with high hardness is used, tools may frequently be damaged. Therefore, there was a problem that only a material with low hardness can be used, and thus only a seamless steel pipe with low endurance can be produced.
  • the present invention was made in view of the aforementioned problems, and an object is to provide a seamless steel pipe with high endurance and hollow spring made of the seamless steel pipe, and a method for producing the seamless steel pipe with excellent production efficiency, with high quality at a reduced cost.
  • a seamless pipe according to the present invention having solved the aforementioned problems is a seamless steel pipe formed from a cylindrical steel material billet through a hot isostatic extrusion step, wherein a depth of a contiguous flaw formed on an inner periphery surface and an outer periphery surface of the steel pipe is 50 ⁇ m or less.
  • the seamless steel pipe of the present invention may have a metallographic structure containing non-metallic inclusions, and a maximum thickness of the non-metallic inclusion in a direction perpendicular to a pipe axis is 50 ⁇ m or less.
  • the maximum thickness of the non-metallic inclusion in a direction perpendicular to the axis of the seamless steel pipe is remarkably small, such as 50 ⁇ m or less, there can be further eliminated parts that would otherwise become origin for fracture when the seamless steel pipe as a spring is continuously extended and contracted.
  • non-metallic inclusion means, for example, glass-like inclusion, such as CaO—SiO 2 —Al 2 O 3 .
  • an average roughness Ra of the inner periphery surface and the outer periphery surface of the steel pipe may be 12.5 ⁇ m or less.
  • the surface is made very smooth, such as the average roughness Ra of at least one of the inner periphery surface and the outer periphery surface is made 12.5 ⁇ m or less, there can be further eliminated parts that would otherwise become origin for fracture, when the seamless steel pipe as a spring is continuously extended and contracted.
  • the steel material may be spring steel.
  • the spring steel can be used for a seamless steel pipe having a high hardness, though in the conventional seamless steel pipe, it was impossible to use the spring steel as a steel material.
  • the hollow spring made of the seamless steel pipe of the present invention in its primary characteristic is obtained by: extruding a heated spring steel material under hot isostatic pressure, to thereby obtain a seamless spring steel pipe with enhanced material cleanliness and surface properties; processing the seamless spring steel pipe into a hollow body in a shape of a coil or a bar or a bar with curved part, and then applying a surface treatment to the hollow body so that the hollow body has compressive residual stress.
  • This hollow spring both weight reduction effect and fatigue strength enhancement can be attained.
  • a method for producing seamless steel pipe which includes a billet molding step, a first heating step, a hot isostatic extrusion step, a second heating step, an extension step, a third heating step and pickling step.
  • a steel material is molded into a cylindrical billet in the billet molding step, the billet is heated in the first heating step, to thereby prepare for hot isostatic extrusion processing in a next step, and the heated billet is subjected to hot isostatic extrusion processing in the hot isostatic extrusion step, to thereby obtain a seamless steel pipe workpiece. Since the hot isostatic extrusion processing is performed here, the seamless steel pipe workpiece can be made with almost no contiguous flaw that may otherwise be formed by slidable contact with the hot isostatic extruder.
  • the seamless steel pipe workpiece in the second heating step, is heated into moldable state, and in the extension step, the seamless steel pipe workpiece is extended by at least one of Pilger mill rolling and drawing processing.
  • the extended seamless steel pipe work-piece in the third heating step, is heated, and in the pickling step, the extended and heated seamless steel pipe work-piece is pickled (washed), to thereby produce a seamless steel pipe having smooth outer and inner peripheries.
  • the method for producing seamless steel pipe of the present invention may further include a straightening step in which bend of the pickled seamless steel pipe is straightened, after the pickling step.
  • the method for producing seamless steel pipe according to the present invention may further include a grinding step in which an inner periphery surface of the heated seamless steel pipe workpiece is subjected to grinding processing, after the second heating step.
  • an inner periphery surface of the seamless steel pipe may be ground after the straightening step.
  • a temperature of the hot isostatic extrusion may be 1,050° C. or more and less than 1,300° C.
  • the hot isostatic extrusion temperature is defined in a specific range, a maximum size and a number per unit area of non-metallic inclusions can be appropriately controlled, and the seamless steel pipe with excellent endurance can be produced.
  • a slow-cooling step may be performed in which the seamless steel pipe workpiece that had been subjected to the hot isostatic extrusion processing is slowly cooled, instead of the second heating step.
  • carbide in the metallographic structure can be granulated by, instead of the second heating step, slowly cooling the seamless steel pipe workpiece that had been subjected to the hot isostatic extrusion processing, the seamless steel pipe having enhanced cold-workability, grindability (machinability), fracture toughness, as well as excellent endurance as described above, can be produced.
  • the seamless steel pipe of the present invention has smooth outer periphery surface and inner periphery surface, since it is produced by hot isostatic extrusion processing. Therefore, there can be eliminated most parts that would otherwise become origin for fracture when the seamless steel pipe as a spring is continuously extended and contracted, and as a result, the seamless steel pipe exhibits excellent endurance, such as a long fatigue life.
  • weight reduction by approximately 30 to 40% can be attained as compared with a solid-core steel material having the same diameter.
  • the hollow spring of the present invention is obtained first as a seamless steel pipe with enhanced material cleanliness and surface properties by extruding a heated spring steel material with fluid pressure; and then as a hollow body in a shape of a coil or a bar or a bar with curved part from the seamless spring steel pipe by applying a surface treatment to the seamless spring steel pipe so that the seamless spring steel pipe has compressive residual stress.
  • a material strength of the hollow spring becomes high, which in turn suppresses permanent transformation (permanent set) and fracture of the spring even under high stress, and design stress can be made higher, to thereby obtain both weight reduction effect and raise of fatigue strength.
  • one technique for enhancing engine performance, one technique is to improve output properties, including an increase of an engine revolution limit and a modification of a breathing port.
  • a movement of a valve operating system becomes a main factor that determines the limit.
  • a rotational movement of a crankshaft transmitted through a cam is transformed into an up-and-down movement of the valve, and the up-and-down movement of the valve is pressed back by a valve spring. Therefore, the engine revolution limit is defined as a point at which the up-and-down movement of the valve spring cannot follow the rotational movement of the cam.
  • it is necessary to increase spring load or reduce inertial mass of a reciprocally moving part, such as the valve including the spring.
  • a suspension spring of automobile suspension is a major factor affecting running performance including on-board comfortability and cornering, and thus merchantability of the automobile.
  • the suspension performance relies chiefly on a basic structure of the vehicle, properties of suspension itself including the suspension spring, and an unsprung weight of tire parts.
  • the suspension spring used for suspending the automobile is designed to sustain a large load since it should support the entire weight of the vehicle, and thus the spring itself has a large weight. Therefore, if the weight of the suspension spring can be reduced, like the valve spring of the engine, the unsprung weight can be also reduced. For example, weight reduction effect of the unsprung weight is ten times larger than body weight reduction effect. Further, the whole structure can be made smaller, leading to not only better on-board comfortability, but also possibility to apply new structural parts.
  • a seamless steel pipe is easily produced by hot isostatic extrusion processing, without piercing the pipe, and thus the number of steps can be reduced. As a result, the seamless steel pipe can be produced with enhanced production efficiency at a reduced cost.
  • the seamless steel pipe can be easily produced, since Mannesmann-piercing or mandrel mill rolling are not performed.
  • FIG. 1 is an enlarged sectional view of a main part of a hot isostatic extruder to be used in a production of a seamless steel pipe according to the present invention.
  • FIG. 2 is a cross sectional view of a hollow coiled spring according to one embodiment of the present invention.
  • FIG. 3 is a graph showing relationships between t/D and weight reduction rate, and between t/D and hole stress.
  • FIG. 4 is a graph showing relationship between t/D and closed height increasing rate, and between t/D and hole stress.
  • FIG. 5 is a cross sectional view of a hollow coiled spring according to another embodiment of the present invention.
  • FIG. 6 is a cross sectional view of a hollow coiled spring according to still another embodiment of the present invention.
  • FIG. 7 shows sectional views of hollow coiled springs according to other embodiments of the present invention.
  • FIGS. 7 ( a ), ( b ) and ( c ) is a sectional view of a main part of the hollow coiled spring according to an embodiment of the present invention.
  • FIG. 8 is an explanatory diagram showing a flow of a preferable method for producing seamless steel pipe according to the present invention.
  • FIG. 9 is a block diagram showing a production process of a hollow coiled spring.
  • FIG. 10 is a conceptual diagram showing inner face shot peening of a hollow coiled spring according to the present invention.
  • FIG. 11 is a graph in which results of endurance test regarding suspension spring in Table 9 are plotted.
  • FIG. 1 is an enlarged sectional view of a main part of a hot isostatic extruder to be used in production of a seamless steel pipe according to the present invention.
  • a seamless steel pipe 1 according to the present invention can be produced at least through a hot isostatic extrusion step in which a billet 2 as a cylindrical steel material is subjected to hot isostatic extrusion processing and a seamless steel pipe workpiece 1 a is formed, as shown in FIG. 1 .
  • the seamless steel pipe 1 can be provided with a remarkably smooth surface (outer periphery surface and inner periphery surface) even from a stage of hot processing, since hot isostatic extrusion processing is performed in a hot isostatic extrusion step.
  • a viscoplastic pressure medium 17 is used when the seamless steel pipe workpiece 1 a is extruded with a hot isostatic extruder 10 . Therefore, friction between the hot isostatic extruder 10 and the seamless steel pipe work-piece 1 a can be remarkably reduced even when a large pressure of, for example, approximately 1 GPa (10,000 atm), is applied and as a result, the seamless steel pipe 1 can be produced that has excellent surface properties with no contiguous flaw or surface roughness.
  • a lubricant prepared by adding graphite to oil is preferred.
  • a depth of the contiguous flaw formed on the inner periphery surface or the outer periphery surface thereof is 50 ⁇ m or less from the surface.
  • contiguous flaw herein means a long scratching flaw continuously formed on the outer periphery surface or the inner periphery surface of the seamless steel pipe 1 from one terminal side to the other terminal side, due to, for example, a contact with a part of the hot isostatic extruder during a production of the seamless steel pipe 1 .
  • the cause when continuous extension and contraction of a coiled spring made of the seamless steel pipe result in cracks or fracture of the coiled spring, the cause generally lies in surface abnormality, such as contiguous flaw formed on the surface of the coiled spring, or a presence of non-metallic inclusions.
  • the depth of the contiguous flaw is made 50 ⁇ m or less, preferably 45 ⁇ m or less, more preferably 40 ⁇ m or less, still more preferably 38 ⁇ m or less, further preferably 35 ⁇ m or less, from the surface of the outer periphery surface or the inner periphery surface.
  • the depth of the contiguous flaw exceeding 50 ⁇ m from the surface of the outer periphery surface or the inner periphery surface is not preferable, since a crack or fracture may start from the contiguous flaw when the coiled spring is continuously extended and contracted.
  • the average roughness Ra exceeding 12.5 ⁇ m is not preferable, since such an excessive surface roughness will generate parts that may become origin for cracks or fracture when the coiled spring is continuously extended and contracted. It should be noted that a lower average roughness Ra is more preferable.
  • the average roughness Ra is preferably 12 ⁇ m or less, more preferably 10 ⁇ m or less, still more preferably 8 ⁇ m or less, further more preferably 4 ⁇ m or less, though, there is no lower limit.
  • the surface roughness Ra is preferably defined by measuring a roughness in a pipe axis direction on the inner periphery surface and the outer periphery surface of the seamless steel pipe.
  • the hot isostatic extruder 10 has: a container 13 having a die 11 at a front end thereof with a support member 12 ; a sealing piston 14 disposed in the container 13 ; a stem 15 for pressing the sealing piston 14 ; and a mandrel 16 penetrating the sealing piston 14 and the stem 15 , for forming an inner bore of a seamless steel pipe workpiece 1 a.
  • This seamless steel pipe workpiece 1 a becomes the seamless steel pipe 1 through steps which will be described later.
  • the billet 2 heated to a high temperature e.g., 1,050° C. or more and less than 1,300° C.
  • a high temperature e.g., 1,050° C. or more and less than 1,300° C.
  • the billet 2 is pressed by the sealing piston 14 through a pressure medium 17 , and the billet 2 is discharged from a space between the die 11 and the mandrel 16 , to thereby obtain the seamless steel pipe workpiece 1 a.
  • the seamless steel pipe 1 having an outer diameter of 30 to 60 mm and a steel thickness of 4 to 7 mm can be easily produced by extruding the billet 2 made of a hollow steel material having an inner diameter of 50 to 60 mm and an outer diameter of 140 to 160 mm, with the hot isostatic extrusion process using the hot isostatic extruder 10 .
  • the inner diameter and the outer diameter of the billet 2 , and the outer diameter and the steel thickness of the seamless steel pipe 1 are not limited to those described above, and can be altered appropriately.
  • a spring steel such as SiCr steel, and SiCrV steel with higher strength.
  • Springs in compliance with a standard of JIS G 3560, JIS G 3561 or the like are preferred, and especially preferred examples include KHV12N, KHV10N, KHV6N, KHV7, CRV, HRS6, SRS600, UHS1900 and UHS2000 (manufactured by Kobe Steel Ltd).
  • the composition preferably is: C of 0.3 to 1.0 mass %, more preferably 0.5 to 0.7 mass % or less; Si of 0.1 to 3.0 mass %, more preferably 1.0 to 3.0 mass %; Mn of 0.05 to 1.5 mass %, more preferably 0.5 to 1.5 mass %; Ni of 0 to 2.5 mass %, more preferably 0.05 to 0.5 mass %; Cr of 0 to 2.0 mass %, more preferably 0.05 to 1.5 mass %; Mo of 0 to 0.8 mass %; V of 0 to 0.8 mass %, more preferably 0.05 to 0.3 mass %; Ti, Nb, Co and W of 0 to 0.5 mass %; and Fe with unavoidable impurities as the remainder.
  • Carbon (C) is a useful element for enhancing tensile strength, improving fatigue property and retaining permanent-transformation resistance of the seamless steel pipe (including seamless steel pipe work-piece).
  • the amount of C is made 0.3 to 1.0 mass % in the present invention.
  • the C amount of 0.5 to 0.7 mass % or narrower range is more preferable.
  • Silicon (Si) is an element having an effect of enhancing tensile strength, improving fatigue property and improving permanent-transformation resistance of the seamless steel pipe by solid solution reinforcement.
  • Si is excessively present in an amount more than 3.0 mass %, the surface is decarburized and flaws increase, leading to poor resistance to fatigue.
  • the amount of Si in the present invention is made 0.1 to 3.0 mass %.
  • the Si amount of 1.0 to 3.0 mass % is more preferable.
  • Manganese (Mn) is an Element Having an Effect of Close Packing and Ordering of pearlite structure, leading to improvement in fatigue property.
  • the amount of Mn is made 0.05 to 1.5 mass % in the present invention.
  • the Mn amount of 0.5 to 1.5 mass % is more preferable.
  • Nickel (Ni) may not be included, but it is preferable to include Ni, since Ni lowers susceptibility to notches and enhances fracture toughness. Ni also has effects of, for example, suppressing fracture in coiling processing, and elongating a fatigue life.
  • Ni be contained in an amount of 0.05 mass % or more.
  • the amount of Ni is made 0 to 2.5 mass % in the present invention.
  • the Ni amount of 0.05 to 0.5 mass % is more preferable.
  • Chromium (Cr) may not be included, but it is preferable to include Cr, since gaps between pearlite lamellae can be made smaller, and fracture strength is increased and permanent-transformation resistance is improved after hot isostatic extrusion or after heat treatment.
  • Cr be contained in an amount of 0.05 mass % or more.
  • the amount of Cr is made 0 to 2.0 mass % in the present invention.
  • the Cr amount of 0.05 to 1.5 mass % is more preferable.
  • Mo Molybdenum
  • Mo may not be included, but may be included since Mo enhances quenching property and has an effect of increasing strength of spring steel.
  • Mo be contained in an amount of 0.2 mass % or more.
  • the amount of Mo in the present invention is made 0 to 0.8 mass % or narrower range.
  • Vanadium (V) May not be Included, but it is Preferable to Include V, Since V is Useful for fining pearlite nodule size and improving workability of the seamless steel pipe. If V is used as a spring material, V is also useful for improving fracture toughness, permanent-transformation resistance and the like of the spring material.
  • V be contained in an amount of 0.05 mass % or more.
  • V is excessively present in an amount more than 0.8 mass %, bainite structure is easily formed during hot isostatic extrusion or the like, leading to shortening of a fatigue life.
  • the amount of V is made 0 to 0.8 mass % in the present invention.
  • the V amount of 0.05 to 0.3 mass % is more preferable.
  • the essential components of the seamless steel pipe of present invention have been described.
  • the remaining part consists substantially of Fe, but may include other components in a trace amount in such a manner that such components do not suffer properties of the seamless steel pipe made of the steel material as described above.
  • the seamless steel pipe containing unavoidable impurities in such an amount is also included in the scope of the present invention.
  • the unavoidable impurities examples include impurities, especially P, S, As, Sb, Sn and the like.
  • the seamless steel pipe 1 of the present invention is made of a spring steel having high hardness. Therefore, though having a hollow structure, the seamless steel pipe 1 has almost the same hardness as those of the conventional solid-core pipe produced using a rolled steel for general structure (JIS G 3101), carbon steel for machine structure (JIS G 4051) and the like.
  • a seamless steel pipe can be produced from a seamless steel pipe workpiece through hot isostatic extrusion processing, in other words, the pipe can be produced without such a making method as piercing, and therefore, the production becomes easy and production cost can be reduced. It should be noted that, after hot isostatic extrusion, the pipe can be provided with desired properties by appropriate cold working, heat treatment and the like.
  • the seamless steel pipe 1 of the present invention can become as hard as Vickers hardness (Hv) of 500 or more, which had not been attained in the prior arts.
  • the seamless steel pipe 1 of the present invention can become still as hard as Vickers hardness (Hv) of 550 or more, Hv 600 or more and Hv 650 or more.
  • metallographic structure thereof contains non-metallic inclusions and the maximum thickness of the non-metallic inclusion in a direction perpendicular to an axis of the seamless steel pipe is preferably 50 ⁇ m or less. It should be noted that, for a member required to have a fatigue life (action of extension and contraction) of more than 10 million times, it is more preferable that the non-metallic inclusions contained therein have the maximum thickness in a direction perpendicular to the axis of the seamless steel pipe of less than 30 ⁇ m, and a number of the non-metallic inclusions per 100 mm 2 of less than 30.
  • the maximum thickness of the non-metallic inclusion in a direction perpendicular to the pipe axis that exceeds 50 ⁇ m is not preferable since, for example, stress is concentrated on the non-metallic inclusions when the seamless steel pipe suffers cyclic fatigue and the like, which may result in fatigue breakdown. On the other hand, there is no limit for lower bound, since it is preferable that non-metallic inclusions be absent from a viewpoint of improving endurance.
  • the maximum thickness and the number per 100 mm 2 of the metallographic structure can be measured by conventional techniques, such as observation of a cross section with a scanning electron microscope.
  • the seamless steel pipe 1 of the present invention fracture does not occur that may otherwise occur when the seamless steel pipe 1 as a spring is continuously extended and contracted, by appropriately controlling the depth of the contiguous flaw, the maximum length, the maximum thickness and the number of the non-metallic inclusion included in the metallographic structure per unit area, the ranges of the components, and the average roughness Ra of the inner periphery surface and the outer periphery surface, and therefore, the seamless steel pipe 1 exhibits excellent endurance.
  • the seamless steel pipe 1 of the present invention can have a higher hardness than the conventional seamless steel pipes.
  • the seamless steel pipe 1 of the present invention is suitable as a material for hollow spring, such as a compression coil hollow spring, a tension coil hollow spring and a torsion hollow spring.
  • a compression coil hollow spring such as a compression coil hollow spring, a tension coil hollow spring and a torsion hollow spring.
  • the resultant compression coil hollow spring has a large spring constant.
  • the hollow spring can be used as a valve spring, suspension spring and the like. As compared with the conventional solid-core valve springs or suspension springs, 30 to 40% of weight reduction can be attained.
  • FIG. 2 is a cross sectional view of a hollow coiled spring as a hollow spring according to one embodiment of the present invention.
  • a hollow coiled spring 31 which is to be used as a suspension spring, a valve spring and the like for automobile, is obtained first as a seamless spring steel pipe with enhanced material cleanliness and surface properties by extruding a heated spring steel material with fluid pressure; and then as a coiled hollow body by coiling and applying a surface treatment to the seamless spring steel pipe so that the seamless spring steel pipe has compressive residual stress.
  • a ratio of a thickness t to an outer diameter D, t/D was made 0.10 to 0.35, preferably 0.20 to 0.30.
  • Table 1 shows relationships between t/D with weight reduction rate and the like.
  • FIG. 3 is a graph showing relationships between t/D and weight reduction rate, and between t/D and hole stress.
  • FIG. 4 is a graph showing relationship between t/D and closed height increasing rate, and between t/D and hole stress.
  • the above-mentioned hollow coiled spring 31 has a hardness Hv of 500 or more, and as shown in FIG. 2 , an outer contour 35 (outer circumference) of the cross section and an inner contour 36 (inner circumference; the hole 33 ) of the cross section are arranged as concentric circles.
  • a relative position of the cross-sectional outer contour 35 and the cross-sectional inner contour 36 is determined based on settings of a coil diameter and a material hardness of the hollow body that forms the above-mentioned hollow coiled spring 31 .
  • the hollow coiled spring 31 according to the present embodiment is obtained first as a seamless steel pipe with enhanced material cleanliness and surface properties by extruding a heated spring steel material with fluid pressure; and then as a coiled hollow body by coiling and applying a surface treatment to the seamless spring steel pipe so that the seamless spring steel pipe has compressive residual stress.
  • it becomes easy to apply uniform compressive residual stress and a material strength of the hollow spring becomes high, which in turn suppresses permanent transformation (permanent set) and fracture of the spring even under high stress, and design stress can be made higher, to thereby obtain both weight reduction effect and raise of fatigue strength.
  • FIG. 5 is a cross sectional view of a hollow coiled spring according to another embodiment of the present invention.
  • a relative position of the cross-sectional inner contour 36 to the cross-sectional outer contour 35 is decentered to outside in a coil diameter direction of the hollow body forming the hollow coiled spring 31 A. Therefore, a thickness t 1 on an inner diameter-side of the hollow coiled spring 31 A is relatively larger than a thickness t 2 on an outer diameter-side.
  • the hollow coiled spring 31 A of FIG. 5 enhances strength on the inner diameter-side where higher stress is applied relative to a stress on the outer diameter-side of the hollow coiled spring 31 A, and thus exhibits improved endurance.
  • FIG. 6 is a cross sectional view of a hollow coiled spring according to still another embodiment of the present invention.
  • the hollow coiled spring 31 B of the present embodiment has a cross-sectional outer contour 35 and a cross-sectional inner contour 36 each in a shape of an ellipsoid which is oblong in a perpendicular direction to an axle of the hollow body coil forming a hollow coiled spring 31 B.
  • the ellipsoids of the cross-sectional outer contour 35 and the cross-sectional inner contour 36 are concentric.
  • a relative position of the cross-sectional outer contour 35 and the cross-sectional inner contour 36 is determined based on settings of a coil diameter and a material hardness of the hollow body.
  • the oblong cross-sectional shape is obtained by rolling treatment of the seamless spring steel pipe.
  • a height of the hollow coiled spring 31 B can be suppressed, and stresses on the inner diameter-side and the outer diameter-side can be made even.
  • FIG. 7 shows sectional views of hollow coiled springs according to other embodiments of the present invention.
  • FIGS. 7 ( a ), ( b ) and ( c ) is a sectional view of a main part of the hollow coiled spring according to an embodiment of the present invention.
  • FIG. 7( a ) shows a hollow coiled spring 31 C having a cross-sectional outer contour 35 in a shape of a oblong ellipsoid, and a cross-sectional inner contour 36 in a shape of a perfect circle.
  • FIG. 7( b ) shows a hollow coiled spring 31 D having a cross-sectional outer contour 35 in a shape of an ovoid in which a curvature radius on a coil inner diameter-side is smaller, and a cross-sectional inner contour 36 in a shape of a perfect circle.
  • FIG. 7( c ) shows a hollow coiled spring 31 E having a cross-sectional outer contour 35 in a shape of basically an ellipsoid (or perfect circle) with flat sides on coil axle directions, and a cross-sectional inner contour 36 in a shape of ellipsoid (or ovoid).
  • the cross-sectional outer contour 35 may be in a shape of rectangular.
  • the hollow springs according to the embodiments of the present invention include modified version of the hollow coiled spring 31 B, 31 C, 31 D and 31 E, in which at least the cross-sectional outer contour of the hollow body forming is not in a circular shape.
  • the present invention may be applied to a hollow stabilizer formed of a hollow body in a shape of a bar having curved parts.
  • the hollow stabilizer has: a main body in a shape of a bar; arms on both ends of the main body; and curved parts that connect the main body and the arms.
  • the present invention may be configured not as a coiled spring but also as a bar-shaped spring, such as a torsion bar without curved parts.
  • FIG. 8 is an explanatory diagram showing a flow of a preferable method for producing seamless steel pipe according to the present invention.
  • the method for producing the seamless steel pipe 1 according to the present invention may include, for example, a billet molding step (FIG. 8 (A)), a first heating step (FIG. 8 (B)), a hot isostatic extrusion step (FIG. 8 (C)), a second heating step (FIG. 8 (D)), an extension step ( FIGS. 8(F) and/or (G)), a third heating step ( FIG. 8(H) ) and a pickling step ( FIG. 8(B) ).
  • the seamless steel pipe 1 as a product can be obtained by performing the steps which will be described in detail below.
  • the method for producing the seamless steel pipe according to the present invention preferably includes a bend straightening step ( FIG. 8(J) ) after the pickling step (FIG. 8 (J)), and more preferably includes a grinding step ( FIG. 8(E) ) after the second heating step ( FIG. 8(D) ).
  • the steel material 2 a is molded into a cylindrical billet 2 (hollow billet).
  • a molding can be performed by forging and the like.
  • the billet 2 is put in a heating furnace for performing heat treatment at 1,050° C. or more and less than 1,300° C., to thereby soften the billet 2 .
  • a heating furnace an electric furnace, a gas furnace and the like can be used.
  • a heating time is not especially limited, as long as the billet 2 is sufficiently softened. The heating time may be appropriately changed depending on a size of the billet 2 .
  • the billet 2 heated to 1,050° C. or more and less than 1,300° C. is subjected to hot isostatic extrusion processing using the hot isostatic extruder 10 described above, to thereby produce the seamless steel pipe workpiece 1 a.
  • the extrusion temperature of the billet 2 is preferably the same as the heating temperature in the first heating step (B), in other words, 1,050° C. or more and less than 1,300° C.
  • the extrusion temperature is optimal at 1,100° C. or more and less than 1,280° C.
  • the recommended extrusion temperature range has a lower limit with somewhat lower bound, such as 1,050° C. or more and less than 1,200° C. When a product quality is considered more important, the range may be set as 1,100° C. or more and less than 1,200° C.
  • the extrusion temperature be made the softening temperature or more.
  • effect of non-metallic inclusions being deformed and sheared due to deformation of metallographic structure depends on relative strength differential between the non-metallic inclusions and the metallographic structure. Therefore, when the extrusion temperature is excessively high and the strength of the metallographic structure decreases more than that of the softened non-metallic inclusions, fining effect is being lost as the crystallization proceeds. Accordingly, it is preferable that the extrusion temperature be a softening temperature or more of the non-metallic inclusions and still retained as low as possible.
  • the extrusion temperature is set lower by 50° C., in other words, 1,050° C. is made the lowest limit of the extrusion temperature.
  • Lower extrusion temperatures than this are not suitable since adverse effect of non-metallic inclusions becomes notable and pushing stress becomes excessively large, leading to poor quality, increased load to equipments and the like.
  • Another feature of the hot isostatic extrusion processing lies in that, when the hot isostatic extrusion processing is performed in the above-mentioned specific temperature range, a surface condition of the seamless steel pipe workpiece 1 a can be made smooth, since friction between the steel material and the tools of the hot isostatic extruder 10 is smaller as compared with the conventional extruder.
  • the surface of the seamless steel pipe workpiece 1 a becomes glossy, the average roughness Ra can be made 50 ⁇ m or less, and crystal grains in the surface become smaller. Therefore, when the seamless steel pipe 1 produced from the same is processed into, for example, a coiled spring, stress becomes maximum at the outermost surface of a hollow spring.
  • the seamless steel pipe workpiece 1 a is heated in a heating furnace.
  • the heating temperature is preferably 650 to 750° C.
  • the heating time may preferably be 0.1 to 1 hour.
  • the heating temperature is lower than 650° C., or the heating time is less than 0.1 hour, the seamless steel pipe workpiece 1 a may not be sufficiently heated, and thus grinding or extension in the next step may not be smoothly performed.
  • the heating temperature exceeding 750° C. is not preferable, since the temperature reaches a quenching temperature.
  • the heating time exceeding 1 hour is not preferable, since the heating effect reaches a saturation, leading to poor cost performance.
  • the grinding step (E) at least an outer surface of the seamless steel pipe is ground, to thereby remove decarburizated portion and fine flaws on the surface, for improving surface properties.
  • both the outer surface and the inner surface may be ground. It should be noted that a size of grinding differs depending on types of steel material, conditions of the first heating step and the second heating step. Therefore, it is preferred that appropriate conditions be set based on experiments performed in advance.
  • Extension of the seamless steel pipe workpiece 1 a can be performed by at least one of Pilger mill rolling (F) and drawing processing (G).
  • the heated seamless steel pipe workpiece 1 a may be extended by appropriate rolling through the drawing processing (G), and then stretching (drawing) using a die 11 through the Pilger mill rolling (F).
  • the Pilger mill rolling (F) is a processing in which the seamless steel pipe work-piece 1 a is made more flattened by being pressed from both sides. Since this processing also stretches the seamless steel pipe workpiece 1 a , the stretching processing in the next step can be omitted.
  • the seamless steel pipe workpiece 1 a is not simply rolled with being pressed from two sides, but can be rolled with being pressed evenly from 3, 4 or more sides, for example. With this processing, the seamless steel pipe workpiece 1 a can be extended while retaining better circularity, and thus the drawing processing (G) can be aggressively made laborsaving.
  • annealing is performed by heating the seamless steel pipe workpiece 1 a at 650 to 750° C. in order to avoid work hardening in the extended (stretched) seamless steel pipe workpiece 1 a .
  • the third heating temperature less than 650° C. is not preferable, since annealing becomes dissatisfactory.
  • the third heating temperature exceeding 750° C. is not preferable, since the annealing effect reaches a saturation, leading to poor cost performance.
  • the annealed seamless steel pipe workpiece 1 a is pickled, to thereby remove oils (pressure medium 17 ) and scales that attach to the seamless steel pipe workpiece 1 a.
  • a seamless steel pipe workpiece 1 a having a desired diameter be produced by performing process from the drawing processing (G), through the third heating step (H) to the pickling step (J), repeated for a certain times.
  • a slow-cooling step in which the heated seamless steel pipe work-piece 1 a is slowly cooled may be performed, instead of the second heating step (D).
  • the seamless steel pipe workpiece 1 a with a reduced diameter is exposed to air, and rapidly cooled down from the above-mentioned temperature range of 1,050° C. or more and less than 1,300° C.
  • This quenching results in the seamless steel pipe workpiece 1 a with extremely high hardness.
  • various steps to be performed afterwards such as the grinding step (E) and the extension step (Pilger mill rolling (F) and/or the drawing processing (G)), cannot be performed.
  • the metallographic structure is changed into an austenite structure by heating, and then in the slow-cooling step (not shown), annealing is performed by slowly cooling the seamless steel pipe workpiece 1 a.
  • the extension step (drawing processing (G) and/or Pilger mill rolling (F)) may be performed without the second heating step. To sum up, there is a merit of reducing the number of production steps.
  • the slow-cooling may be performed with a thermal insulating machine in which temperature and slow-cooling speed are controlled, so that the hot isostatic extrusion is performed without rapidly cooling the seamless steel pipe workpiece 1 a.
  • a slow-cooling rate be 0.1 to 0.3° C./sec.
  • the slow-cooling rate is more than 0.3° C./sec, annealing effect cannot be obtained from slow cooling.
  • the slow-cooling rate is below 0.1° C./sec, a time period required before the extension step becomes too long, leading to poor production efficiency.
  • a steel raw material processed into a hollow billet is heated, softened and subjected to hot isostatic extrusion processing to thereby obtain a seamless pipe. Therefore, a seamless steel pipe having a small diameter (e.g. 30 to 60 mm) can be produced from a hollow billet having a large diameter.
  • a cross-sectional area of the seamless steel pipe can be reduced (for example, by Pilger mill, drawing, or stretching) to the predetermined size.
  • hydrostatic extrusion processing has smaller friction with tools, and therefore, the seamless pipe produced by the above-mentioned production method has glossy appearance and surface crystal grains become fine.
  • the production step of the seamless spring steel pipe as a whole is simplified, which makes it possible to produce a hollow spring with high quality at a reduced cost, and in turn to use a hollow spring in a vehicle in a practice basis.
  • a high-quality seamless steel pipe with smooth outer periphery surface and inner periphery surface can be produced.
  • such a seamless steel pipe can be produced without performing Mannesmann-piercing and mandrel mill rolling, leading to lessen labor and simplify steps up to completion of a product, and thus the seamless steel pipe can be produced at a reduced cost.
  • FIG. 9 is a block diagram showing a production process of a hollow coiled spring 31 .
  • the hollow coiled spring 31 is obtained through a hot isostatic extrusion step 7 , a grinding step 9 , a rolling step 11 , a coil forming step 13 , a heat treatment step 15 , an end face grinding step 17 , a shot peening step 19 , a setting step 21 , and a coating step 23 in this order.
  • the hot isostatic extrusion step 7 and the grinding step 9 in FIG. 9 correspond to the above-mentioned hot isostatic extrusion step ( FIG. 8(C) ) and the grinding step (FIG. 8 (E)), the detailed steps from the hot isostatic extrusion step 7 to the grinding step 9 in FIG. 9 are substantially the same as the steps explained with respect to FIG. 8 .
  • the seamless steel pipe 2 of FIG. 8 made of a spring steel material is heated and softened; hot isostatic extrusion processing is performed to thereby obtain a seamless steel pipe; and the cross-sectional area of the seamless steel pipe is reduced to a predetermined diameter.
  • the hot isostatic extrusion processing molding is performed using the spring steel material in a fluid state, and therefore, a seamless pipe with an outer diameter of, for example, 30 to 60 mm is directly produced from a hollow billet with an outer diameter of, for example, 300 mm or more.
  • the hot isostatic extrusion processing be performed while the above-mentioned spring steel material is heated to 1,050° C. or more and less than 1,300° C. With this configuration, the spring steel material is not in a molten state but in a softened state, which secures fluidability under ultrahigh pressure.
  • the seamless spring steel pipe after grinding is stretched by rolling. Due to this rolling step 11 , the processing amount in the next coil forming step 13 can be reduced.
  • a seamless spring steel pipe after rolling is formed into a hollow body in a shape of a coil.
  • the hollow body in a shape of a coil is provided with elasticity as a spring by quenching and tempering heat treatment.
  • this step it is also possible to provide the inner surface of the hole 3 with a compressive residual stress of approximately 100 MPa by performing nitriding treatment as surface treatment, after quenching and tempering heat treatment.
  • the outer surface of the hollow coiled spring 31 and the inner surface of the hole 3 undergo a surface treatment so that the outer and inner surfaces have compressive residual stress. It should be noted that rendering of compressive residual stress to the inner surface can be omitted.
  • the inner surface of the hole 3 can be provided with a compressive residual stress of 200 MPa or less by carburization quenching and tempering heat treatment.
  • the compressive residual stress may be applied by inner face shot peening, which will be described later, to the inner surface of the hole 3 after quenching and tempering heat treatment.
  • compressive residual stress may be applied to the inner surface of the hole 3 , by: applying an oil-temper treatment to the seamless spring steel pipe; forming a hollow body in a shape of a coil in the coil forming step 13 ; performing a heat treatment for removing distortion; and performing the quenching and tempering heat treatment plus nitriding treatment, or carburization quenching and tempering heat treatment, or quenching and tempering heat treatment plus inner face shot peening.
  • an end face of the hollow body in a shape of a coil is ground to perform end face treatment.
  • hard fine grains are collided with the outer surface of the coiled hollow body, to thereby perform surface treatment which applies compressive residual stress to the outer surface.
  • FIG. 10 is a conceptual diagram showing inner face shot peening.
  • a shot nozzle 55 of a shot peening device utilizing air pressure is directed to a hole 53 of one end 51 of a hollow body 49 in a shape of a coil, and shot peening is performed. Subsequently, this shot peening is performed also from the other end of the hollow body 49 .
  • a diameter of a shot grain is made 1 ⁇ 3 or less of the diameter of the hole 53 , to surely apply compressive residual stress to the hole 53 .
  • coating is performed if desired, to thereby obtain a coated hollow coiled spring 31 .
  • the coil forming step in the present embodiment is replaced with an arm forming step.
  • a cross section of the curved part of the hollow stabilizer is designed in similar manner as in the hollow coiled springs 31 , 31 A and 31 B, and the thickness is adjusted in a direction of curvature radius at the curved part.
  • the entire part of the hollow stabilizer may have the oblong cross-sectional shape.
  • Table 2 shows a comparison between weight reduction effects of coiled spring.
  • coiled springs used were: a coiled spring (solid-core material) made of SiCr steel as solid-core material; a conventional hollow coiled springs (conventional hollow material) obtained using S45C or the like; and hollow coiled springs as example product made of SiCr steel or high-strength SiCrV steel, each having a coil inner diameter of ⁇ 45 mm and an applied maximum load of 2750 N.
  • the conventional hollow coiled spring made of low-carbon steel exhibited hardness (Hv) of 440 and a tensile strength (TS) of 1,480 MPa after quenching.
  • Hv hardness
  • TS tensile strength
  • the performances are not inferior to those of solid-core material as shown in FIG. 10 , and the weight is rather smaller.
  • Table 3 shows examples of chemical composition of high-strength SiCrV steel.
  • a steel A and a steel B have been developed not as SiCr steel compliant with JIS standard, but vanadium (V) and the like are added thereto, to surly obtain the above-mentioned weight reduction effect as high-strength SiCrV steel.
  • V vanadium
  • Table 3 shows examples of chemical composition of high-strength SiCrV steel.
  • cylindrical billets were made of KHV10N (manufactured by Kobe Steel Ltd.) as steel material.
  • the billets were formed so as to have the outer diameter of 143 mm and the inner diameter of 52 mm.
  • the billets were heated at 950 to 1400° C. as shown in Table 1.
  • Each of the heated billets for Test No. 1 to 9 was subjected to hot isostatic extrusion processing using a hot isostatic extruder at a corresponding temperature (extrusion temperature), to thereby produce a seamless steel pipe.
  • the seamless steel pipes of Test No. 1 to 9 were subjected to spheroidizing annealing processing at 680° C.
  • a pressure medium for the hot isostatic extrusion As a pressure medium for the hot isostatic extrusion, a pressure medium was used including synthetic oil as a matrix, prepared by adding graphite to molybdenum disulfide-containing lubricating oil.
  • the maximum thickness ( ⁇ m) and the number per unit area (number/100 mm 2 ) were measured by observing a cross section with a scanning electron microscope.
  • Test No. 7 to 9 with the extrusion temperatures of 1,300° C. or more, the maximum thickness of the non-metallic inclusion in the seamless steel pipe was large (58 ⁇ m or more), and the number of non-metallic inclusions was large (42 or more inclusions/100 mm 2 ). Surface roughness was also observed.
  • Test No. 1, 2 and 7 to 9 are Comparative Examples.
  • Test No. 3 to 6 are Examples.
  • the extrusion temperature of the billet during the hot isostatic extrusion step is preferably made 1,050° C. or more and less than 1,300° C.
  • the extrusion temperature is preferably made 1,050 to 1,250° C., in order to surely suppress the number and the size of non-metallic inclusions in the metallographic structure that affects endurance of coiled spring.
  • extrusion temperature is preferably made 1,050° C. or more and less than 1,200° C.
  • the temperature is preferably made 1,100° C. or more and less than 1,200° C.
  • the surface of the seamless steel pipe can be made smooth.
  • coiled springs were produced from: the seamless steel pipes which meet requirements of the present invention; the seamless steel pipe which do not meet requirements of the present invention; and a solid-core steel material.
  • a fatigue test was conducted. It should be noted that the steel materials are the same as in ⁇ Example 2>>.
  • the coiled spring of Test No. 11 has surface flaw (artificial flaw corresponding to contiguous flaw), formed on the outer periphery surface and the inner periphery surface thereof.
  • the coiled spring of Test No. 11 was obtained by: forming a seamless steel pipe under the same conditions as those in Test No. 10; a surface flaw with a depth of more than 50 ⁇ m was formed on the seamless steel pipe by filing the outer periphery surface and sliding a reeler having rough surface over the inner periphery surface; and processing the seamless steel pipe into a coiled spring.
  • a coiled spring of Test No. 12 had non-metallic inclusions having a maximum thickness in a direction perpendicular to the pipe axis of more than 50 ⁇ m, in the metallographic structure.
  • a seamless steel pipe was produced by hot isostatic extrusion processing at 1,350° C., and from this seamless steel pipe, a coiled spring (hollow product) having the above-mentioned properties was produced.
  • a coiled spring of Test No. 13 is a conventional solid-core coiled spring.
  • a solid-core steel material was produced by hot isostatic extrusion in which the same solid-core billet as in Test No. 10 to 12 was used under the same conditions as in Test No. 10 to 12, except that a mandrel was not used; and from this steel material, a coiled spring (solid-core product) having an outer diameter of 76.0 mm, a height of 153.5 mm, and a winding number of 6.76 was produced.
  • the fatigue test was performed as a fatigue test of single unit, in which action of extension and contraction was repeated a predetermined times (400,000 times).
  • the hollow coiled spring meeting the requirements of the present invention shows results equivalent to the solid-core coiled spring (Test No. 13).
  • valve spring in Table 6 was processed and adjusted to have a wire diameter of ⁇ 5.6 mm, a hole diameter of ⁇ 2.8 mm (thickness of 1.4 mm), an outer maximum shearing stress of 950 MPa, and hardness after heat treatment (Hv) of 620.
  • Hv hardness after heat treatment
  • the results of endurance test of the suspension spring in Table 9 were obtained using a hollow coiled spring formed of a seamless steel pipe made of the steel A in Table 3 at an extrusion temperature E in Table 6, the hollow coiled spring having the hardness altered by heat treatment.
  • the hollow coiled spring to be tested was processed and adjusted to have a wire diameter of ⁇ 10.0 mm, a hole diameter of ⁇ 5.0 mm (thickness of 2.5 mm), and an outer maximum shearing stress of 1,100 MPa.
  • FIG. 11 is a graph in which results of endurance test in Table 9 are plotted.
  • Table 11 shows results of a hollow stabilizer endurance test. The results were obtained using the steel A in Table 3 processed and adjusted to have a wire diameter of ⁇ 25.0 mm, a hole diameter of ⁇ 12.5 mm (thickness of 6.25 mm), an outer maximum principal stress of ⁇ 700 MPa, and a hole-side maximum principal stress of ⁇ 450 MPa.
  • the hollow stabilizer made of the conventional S40C has a hardness Hv 420, and fracture was observed on an outer surface after 85,000 times (1st operation) and 95,000 times (2nd operation).
  • the hollow stabilizer of the present Example of hardness Hv 515, fracture was observed on an inner surface of the hole (surface of the hole) after 246,000 times (1st operation) and 313,000 (2nd operation), which is approximately 3 times of a duration life as compared with the conventional product.
  • no fracture was observed after 500,000 times of repetition.
  • glass powder instead of the pressure medium 17 used in hot isostatic extrusion processing, glass powder may be used and thus hot glass-lubricating extrusion processing may be performed.
  • the present invention can be used as: a hollow spring material having a squared U-shape, such as a stabilizer; a hollow bar material, such as drive shaft; and a frame material for buildings or bicycles.

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US14/453,747 Active 2028-11-17 US10118208B2 (en) 2007-03-14 2014-08-07 Hollow spring utilizing seamless steel pipe
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US15/268,268 Abandoned US20170001226A1 (en) 2007-03-14 2016-09-16 Process for manufacturing seamless steel pipe, hollow spring utilizing seamless steel pipe

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US20130118649A1 (en) * 2010-03-23 2013-05-16 Chuo Hatsujo Kabushiki Kaisha Method for manufacturing spring
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US20170348826A1 (en) * 2016-06-06 2017-12-07 Superior Shot Peening, Inc. Tools and related methods for cold working fluid ends
US9844852B1 (en) 2016-06-06 2017-12-19 Superior Shot Peening, Inc. Shot peening tools and related methods
US10413951B2 (en) 2015-09-14 2019-09-17 Seyed Sajjad Jamali Hydrostatic extrusion system and method for producing high strength seamless pipes
US10987779B2 (en) * 2017-06-28 2021-04-27 Mitsubishi Steel Mfg. Co., Ltd. Hollow spring and manufacturing method thereof
CN113333498A (zh) * 2021-04-28 2021-09-03 孟祥平 一种不锈钢无缝钢管的自动加工工艺
US11805945B2 (en) 2019-09-18 2023-11-07 Robert G. Nothum, Jr. Heat exchange tubes for fryer in food process line

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Cited By (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100289198A1 (en) * 2009-04-28 2010-11-18 Pete Balsells Multilayered canted coil springs and associated methods
US20120070682A1 (en) * 2009-05-15 2012-03-22 Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel, Ltd.) Hollow seamless pipe for high-strength springs
US9689051B2 (en) * 2009-05-15 2017-06-27 Kobe Steel, Ltd. Hollow seamless pipe for high-strength springs
US20130118649A1 (en) * 2010-03-23 2013-05-16 Chuo Hatsujo Kabushiki Kaisha Method for manufacturing spring
US9227300B2 (en) * 2010-12-03 2016-01-05 Nhk Spring Co., Ltd. Hollow spring and method for manufacturing same
US20130241121A1 (en) * 2010-12-03 2013-09-19 Nhk Spring Co., Ltd. Hollow spring and method for manufacturing same
US9776228B2 (en) * 2012-09-14 2017-10-03 Sandvik Materials Technology Deutschland Gmbh Pilger rolling train
US20150258590A1 (en) * 2012-09-14 2015-09-17 Sandvik Materials Technology Deutschland Gmbh Pilger rolling train
KR20150067195A (ko) * 2012-09-14 2015-06-17 산드빅 마테리알스 테크놀로지 도이칠란트 게엠베하 필거 롤링 트레인
KR102110003B1 (ko) * 2012-09-14 2020-05-12 산드빅 마테리알스 테크놀로지 도이칠란트 게엠베하 필거 롤링 트레인
US10413951B2 (en) 2015-09-14 2019-09-17 Seyed Sajjad Jamali Hydrostatic extrusion system and method for producing high strength seamless pipes
US20170348826A1 (en) * 2016-06-06 2017-12-07 Superior Shot Peening, Inc. Tools and related methods for cold working fluid ends
US9844852B1 (en) 2016-06-06 2017-12-19 Superior Shot Peening, Inc. Shot peening tools and related methods
US10252398B2 (en) * 2016-06-06 2019-04-09 Superior Shot Peening, Inc. Tools and related methods for cold working fluid ends
US10800005B2 (en) 2016-06-06 2020-10-13 Superior Shot Peering, Inc. Shot peening tools and related methods
US11794306B1 (en) 2016-06-06 2023-10-24 Superior Shot Peening, Inc. Tools and related methods for cold-working fluid ends
US10987779B2 (en) * 2017-06-28 2021-04-27 Mitsubishi Steel Mfg. Co., Ltd. Hollow spring and manufacturing method thereof
US11805945B2 (en) 2019-09-18 2023-11-07 Robert G. Nothum, Jr. Heat exchange tubes for fryer in food process line
CN113333498A (zh) * 2021-04-28 2021-09-03 孟祥平 一种不锈钢无缝钢管的自动加工工艺

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CN101626848B (zh) 2012-04-04
US20130239637A1 (en) 2013-09-19
US20140346721A1 (en) 2014-11-27
EP2145705A4 (en) 2013-04-24
EP2145705A1 (en) 2010-01-20
US20170001226A1 (en) 2017-01-05
KR20130087626A (ko) 2013-08-06
EP2703097B1 (en) 2019-05-01
US10118208B2 (en) 2018-11-06
CN101626848A (zh) 2010-01-13
EP2703097A1 (en) 2014-03-05
WO2008111200A1 (ja) 2008-09-18
US9482302B2 (en) 2016-11-01
EP2145705B1 (en) 2016-08-24
KR20100015369A (ko) 2010-02-12

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