WO2018029713A2 - Porte-fusée et sa fabrication - Google Patents

Porte-fusée et sa fabrication Download PDF

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Publication number
WO2018029713A2
WO2018029713A2 PCT/IN2017/050344 IN2017050344W WO2018029713A2 WO 2018029713 A2 WO2018029713 A2 WO 2018029713A2 IN 2017050344 W IN2017050344 W IN 2017050344W WO 2018029713 A2 WO2018029713 A2 WO 2018029713A2
Authority
WO
WIPO (PCT)
Prior art keywords
stem
knuckle
tie rod
rod arm
electron beam
Prior art date
Application number
PCT/IN2017/050344
Other languages
English (en)
Other versions
WO2018029713A3 (fr
Inventor
Babasaheb KALYANI
Valmik BHAVAR
Prakash KATTIRE
Sandeep THAKARE
Sourabh SINDAGI
Manoj UKHANDE
Vijaykumar KHASNIS
Madan TAKALE
Rajkumar SINGH
Original Assignee
Bharat Forge Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Bharat Forge Limited filed Critical Bharat Forge Limited
Publication of WO2018029713A2 publication Critical patent/WO2018029713A2/fr
Publication of WO2018029713A3 publication Critical patent/WO2018029713A3/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K1/00—Making machine elements
    • B21K1/74—Making machine elements forked members or members with two or more limbs, e.g. U-bolts, anchors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K15/00—Electron-beam welding or cutting
    • B23K15/0026—Auxiliary equipment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K15/00—Electron-beam welding or cutting
    • B23K15/0033—Preliminary treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K15/00—Electron-beam welding or cutting
    • B23K15/0046—Welding
    • B23K15/0053—Seam welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K15/00—Electron-beam welding or cutting
    • B23K15/0046—Welding
    • B23K15/0093—Welding characterised by the properties of the materials to be welded
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K15/00—Electron-beam welding or cutting
    • B23K15/04—Electron-beam welding or cutting for welding annular seams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K15/00—Electron-beam welding or cutting
    • B23K15/06—Electron-beam welding or cutting within a vacuum chamber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K33/00—Specially-profiled edge portions of workpieces for making soldering or welding connections; Filling the seams formed thereby
    • B23K33/004—Filling of continuous seams
    • B23K33/006—Filling of continuous seams for cylindrical workpieces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K33/00—Specially-profiled edge portions of workpieces for making soldering or welding connections; Filling the seams formed thereby
    • B23K33/004—Filling of continuous seams
    • B23K33/008—Filling of continuous seams for automotive applications
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D7/00—Steering linkage; Stub axles or their mountings
    • B62D7/18—Steering knuckles; King pins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/006—Vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/02—Iron or ferrous alloys
    • B23K2103/04—Steel or steel alloys
    • 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
    • C21D9/50—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for welded joints

Definitions

  • the present invention relates to manufacturing of steering knuckle used in automotive applications.
  • the present invention relates to manufacturing of multi piece steering knuckle.
  • Steering knuckle is one of the main components used in the suspension system of automobiles.
  • the steering knuckle is the connection between a tie rod, an axle beam and a wheel hub. It is connected to the axle beam by using a king pin. Another end of the steering knuckle is connected to the tie rod.
  • the wheel hub is fixed over the steering knuckle using bearings.
  • Steering knuckles are typically manufactured either by forging or casting technique. Since steering knuckle is subjected to different types of fatigue loading conditions, forging is popular and preferred method of manufacturing over casting.
  • Patent US5624011 discloses a forged steering knuckle which has integrated steering and tie rod arms, a spindle, and support elements for a drum brake assembly. Further, a one-piece steering knuckle assembly wherein a flanged body, wheel spindle and tie rod are formed as a one-piece forging and wherein the flanged body is forged in the form of a brake spider to accommodate disc brakes is disclosed in US5219176.
  • integral steering knuckle is having a spindle (Stem) at one side and a tie rod arm at another side, part complexity increases which makes it difficult to manufacture especially by forging.
  • This complex desig of integral steering knuckle may require number of forging operations to get the final shape. Further, extra care need to be taken during each forging operation to avoid forging defects like under-fill and cracks which also limits part cycle time for mass production. Still further, since steering knuckle is forged from a single billet, the percentage utilisation of the material is also low. All of these above mentioned factors contribute to increase the overall manufacturing cost.
  • Another concern of integral design is the weight of steering knuckle.
  • the steering knuckle carries the power thrust and hence it must be very strong, rigid and also as light as possible. Therefore, in view of this, material optimization and geometric optimization is the real need for the automobile industry without affecting strength and performance of steering knuckle.
  • integral complex design of steering knuckle and forging as a manufacturing process puts restrictions to weight optimization.
  • Still another object of the present invention is to provide a hybrid method for manufacturing steering knuckles which combines forging and welding.
  • FigurelA illustrates existing design of an integral steering knuckle
  • Figure IB illustrates existing manufacturing process sequence
  • Figure 2 illustrates separated parts of steering knuckle, namely tie rod arm, stem and base knuckle;
  • Figure 3 illustrates steering knuckle in accordance with one embodiment of the present invention
  • Figure 4 illustrates a method of manufacturing a steering knuckle in accordance with one embodiment of the present invention.
  • Figure 5 illustrates a method of manufacturing a steering knuckle in accordance with another embodiment of the present invention.
  • the present invention provides a method of manufacturing a steering knuckle; said method comprising forging a tie rod arm, a stem, and a base knuckle separately; and electron beam welding said tie rod arm and said stem to said base knuckle to form the steering knuckle.
  • tie rod arm, stem and base knuckle are separately manufactured by hot forging.
  • the method further comprises identifying the critical stress areas of a steering knuckle near stem and tie rod arm in order to split component away from the high stress zones; said identification is carried out by FEA(Finite element analysis) considering various loading and boundary conditions, thereby deciding a split line of arm and spindle on FEA results.
  • FEA Finite element analysis
  • a steering knuckle comprising a base knuckle (12); a tie rod arm (14); and a stem (16), wherein said tie rod arm (14) comprises a pilot stub or a pilot hole, said tie rod arm being electron beam welded to said base knuckle (12); said stem (16) comprises a pilot stub or a pilot hole, said stem being electron beam welded to said base knuckle (12), and said base knuckle (12) comprises a pilot stub or a pilot hole.
  • a method of manufacturing steering knuckle comprises forging a tie rod arm, a stem (spindle), and a base knuckle separately; and electron beam welding said tie rod arm and said stem to said base knuckle to form the steering knuckle.
  • a steering knuckle obtained by the method of the present invention.
  • Said steering knuckle (100) comprises a base knuckle (12); a tie rod arm (14); and a stem (16), wherein said tie rod arm (14) being electron beam welded to said base knuckle (12); and said stem (16) being electron beam welded to said base knuckle (12).
  • said stem (16) being electron beam welded to said base knuckle (12) at a joint (18).
  • said tie rod arm (14) being electron beam welded to said base knuckle (12) at a joint (18').
  • Said steering knuckle is illustrated in figure 3 of the accompanying drawings.
  • Each of the base knuckle (12); the tie rod arm (14); and the stem (16) comprises either pilot stub or pilot hole in order to fix or connect or engage the tie rod arm and the stem to the base knuckle.
  • the chassis system of heavy duty vehicle typically includes a steering knuckle.
  • the steering arm or tie rod arm can be bolted or integral to the steering knuckle.
  • Figure 1A shows existing integral steering knuckle where tie rod arm is an integral part of steering knuckle. This type of integral design is preferred since it avoids tie rod-knuckle joint and reduces assembly time.
  • this integration of tie rod arm to the steering knuckle increases the overall part complexity and makes it difficult to manufacture especially by forging. Moreover, a higher capacity forging equipment may be required for forging due to increase in part weight and complexity.
  • This type of integral steering knuckle is manufactured from single billet by using a hot forging method.
  • the inventors particularly focussed on providing a steering knuckle which is formed by electron beam welding of separately forged tie rod arm and stem to the base knuckle.
  • the key aspect of the invention is to identify the critical stress areas of a steering knuckle near stem and tie rod arm so that the component can be split away from these high stress zones.
  • FEA Finite element analysis
  • the split line of tie rod arm and stem is decided based on this FEA results.
  • Figure 2 shows separated parts of integral steering knuckle like tie rod arm, stem and base knuckle. In one embodiment of the present invention the split line is present 10 mm to 30 mm away from maximum stress concentration area.
  • the tie rod arm and stem part may be produced by using cold / warm forging which can save the energy required for heating up to forging temperature.
  • each of these individual parts can be precision forged with effective utilisation of material. This in turn can reduce initial raw material required to produce said steering knuckle.
  • each part can be precision forged on a low capacity forging equipments with minimum forging operations.
  • the stem can be hollow or solid thus reducing the material requirement as well as lightweighting of the steering knuckle.
  • the optimized base knuckle and hollow design of stem can result in 8 to 14 % weight saving of integral steering knuckle.
  • said electron beam welding is specifically chosen since it provides certain advantages as compared to other competitive joining technologies such as laser and friction welding.
  • electron beam welding is carried out in a vacuum environment which ensures weld quality.
  • the EBW method of the present invention provides very deep welds as compared to laser welding method wherein weld depth is limited. It is found that micro- structural and mechanical properties of EBW joint are superior than the friction or laser weld joint.
  • Joint designing is very critical aspect in case of electron beam welding.
  • stem welding such as pin and bore type joint , pilot hole and pilot stub can be used.
  • pilot hole and pilot stub arrangement is used to connect the stem and tie rod to the base knuckle.
  • the electron beam welding of the stem comprises circumferential welding.
  • the method comprises placing said stem over the base knuckle; and performing circumferential electron beam welding (EBW) while rotating said base knuckle and stem provided on fixture.
  • EBW circumferential electron beam welding
  • electron beam welding of the base knuckle and the tie rod arm comprises holding said base knuckle and said tie rod arm on a special fixture in a ready to join condition and performing the EBW from one side by using linear welding.
  • Figure 3 shows stem and tie rod arm joint.
  • the method comprises machining of stub or hole of the stem and/or the tie rod and/ or base knuckle which is carried out after forging of each individual component.
  • the method comprises forging the components, namely the base knuckle, the stem and the tie rod arm separately; optionally, demagnetizing one or more said components; placing said parts over specially designed fixtures in ready to weld condition; heating said components at a temperature of about 300 to 400° C; performing electron beam welding to form the steering knuckle; and control cooling said steering knuckle.
  • said electron beam welding is carried out in two steps. First tack welding is carried out to secure joint to be welded followed by full depth welding. The method is shown in figure 5. [0036] It is observed that hardness in weld zone increases due to micro-structural changes (martensite formation in case of steel alloy).
  • a steering knuckle was prepared by the following procedure.
  • a base knuckle, a stem and a tie rod arm were separately forged by hot forging.
  • the forged components were then demagnetized and placed over specially designed fixtures in ready to weld condition. These components were then heated around 300-400° C.
  • the stem and tie rod arm were electron beam welded to the base knuckle to form the steering knuckle followed by control cooling.
  • the weight of the steering knuckle was found to be around 27kg compared to weight of integrated knuckle (30kg) made without separate forging of components and electron beam welding technique.
  • the weight was reduced by using hollow stem and optimized design.
  • Microstmcture, hardness and fatigue testing were performed on the parts. Microstmcture testing showed that the microstmcture at EBW zone and base material is same i.e. tempered martensite. Hardness testing showed that the hardness at the EBW zone and base material is similar in the range of 320 ⁇ 340 HV. Component level fatigue tests showed that the fatigue strength of the steering knuckle is comparable with the fatigue strength of steering knuckle produced using conventional process. Moreover, the failure location was not in the EBW zone.
  • the present invention provides the following advantages over the conventional methods of integral steering knuckle manufacturing:

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Steering-Linkage Mechanisms And Four-Wheel Steering (AREA)

Abstract

La présente invention concerne un procédé de fabrication d'un porte-fusée, ledit procédé consistant à forger séparément un bras de barre de liaison, une tige et une articulation de base; et souder par faisceau d'électrons ledit bras de barre de liaison et ladite tige à ladite articulation de base pour former le porte-fusée. La présente invention concerne également un porte-fusée (100) comprenant une articulation de base (12) présentant un embout pilote ou un trou pilote; un bras de barre de liaison (14); et une tige (16), ledit bras de barre de liaison (14) comprend un embout pilote ou un trou pilote, ledit bras de barre de liaison étant soudé par faisceau d'électrons à ladite articulation de base (12); et ladite tige (16) comprenant un embout pilote ou un trou pilote, ladite tige étant soudée par faisceau d'électrons à ladite articulation de base (12). FIG. 1: Hot forging%%%Forgeage à chaud Shot blasting%%%Décapage à la grenaille Heat treatment%%%Traitement thermique Final machining%%%Usinage final
PCT/IN2017/050344 2016-08-12 2017-08-12 Porte-fusée et sa fabrication WO2018029713A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IN201621027563 2016-08-12
IN201621027563 2016-08-12

Publications (2)

Publication Number Publication Date
WO2018029713A2 true WO2018029713A2 (fr) 2018-02-15
WO2018029713A3 WO2018029713A3 (fr) 2018-08-16

Family

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Family Applications (1)

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PCT/IN2017/050344 WO2018029713A2 (fr) 2016-08-12 2017-08-12 Porte-fusée et sa fabrication

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20220185369A1 (en) * 2020-12-16 2022-06-16 Hendrickson Usa, L.L.C. Knuckle for a self-steering axle/suspension system

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3908480A (en) 1970-10-13 1975-09-30 Dayton Walther Corp Interlocking knuckle assembly
US5219176A (en) 1989-11-02 1993-06-15 James Mitchell One-piece steering knuckle assembly
US5624011A (en) 1995-03-21 1997-04-29 White; Jay D. Steer axle brake assembly

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4002286A (en) * 1975-11-03 1977-01-11 Simon Joseph A Method of manufacturing a steering knuckle and spindle
US6639173B1 (en) * 2003-04-30 2003-10-28 General Electric Company Electron beam welding method providing post-weld heat treatment
CN2693597Y (zh) * 2004-01-30 2005-04-20 重庆力帆实业（集团）有限公司 四轮摩托车的转向节
DE102008060205A1 (de) * 2008-12-04 2010-06-10 Rolls-Royce Deutschland Ltd & Co Kg Verfahren zur Herstellung eines geschweißten Rotors für ein Gasturbinentriebwerk
US8378248B2 (en) * 2010-05-21 2013-02-19 General Electric Company System and method for heat treating a weld joint
DE102012201353A1 (de) * 2012-01-31 2013-08-01 Schaeffler Technologies AG & Co. KG Verfahren und Vorrichtung zum Verbinden einer Welle mit einem Schaufelrad eines Turboladers
CN103407490A (zh) * 2013-08-12 2013-11-27 湖南中联重科车桥有限公司 一种转向节、车辆和该转向节的制造方法

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3908480A (en) 1970-10-13 1975-09-30 Dayton Walther Corp Interlocking knuckle assembly
US5219176A (en) 1989-11-02 1993-06-15 James Mitchell One-piece steering knuckle assembly
US5624011A (en) 1995-03-21 1997-04-29 White; Jay D. Steer axle brake assembly

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20220185369A1 (en) * 2020-12-16 2022-06-16 Hendrickson Usa, L.L.C. Knuckle for a self-steering axle/suspension system
US11891141B2 (en) * 2020-12-16 2024-02-06 Hendrickson Usa, L.L.C. Knuckle for a self-steering axle/suspension system

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