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
  • B21K1/28—Making machine elements wheels; discs
  • B21K1/40—Making machine elements wheels; discs hubs
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
  • B21J9/00—Forging presses
  • B21J9/02—Special design or construction
  • B21J9/025—Special design or construction with rolling or wobbling dies
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B60—VEHICLES IN GENERAL
  • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
  • B60B27/00—Hubs
  • B60B27/0078—Hubs characterised by the fixation of bearings
  • B60B27/0084—Hubs characterised by the fixation of bearings caulking to fix inner race
• • 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
  • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
  • F16C19/00—Bearings with rolling contact, for exclusively rotary movement
  • F16C19/02—Bearings with rolling contact, for exclusively rotary movement with bearing balls essentially of the same size in one or more circular rows
  • F16C19/14—Bearings with rolling contact, for exclusively rotary movement with bearing balls essentially of the same size in one or more circular rows for both radial and axial load
  • F16C19/18—Bearings with rolling contact, for exclusively rotary movement with bearing balls essentially of the same size in one or more circular rows for both radial and axial load with two or more rows of balls
  • F16C19/188—Bearings with rolling contact, for exclusively rotary movement with bearing balls essentially of the same size in one or more circular rows for both radial and axial load with two or more rows of balls with at least one row for radial load in combination with at least one row for axial load
• • 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
  • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
  • F16C33/00—Parts of bearings; Special methods for making bearings or parts thereof
  • F16C33/30—Parts of ball or roller bearings
  • F16C33/58—Raceways; Race rings
  • F16C33/64—Special methods of manufacture
• • 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
  • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
  • F16C35/00—Rigid support of bearing units; Housings, e.g. caps, covers
  • F16C35/04—Rigid support of bearing units; Housings, e.g. caps, covers in the case of ball or roller bearings
  • F16C35/06—Mounting or dismounting of ball or roller bearings; Fixing them onto shaft or in housing
  • F16C35/063—Fixing them on the shaft
• • 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
  • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
  • F16C43/00—Assembling bearings
  • F16C43/04—Assembling rolling-contact bearings
• • 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
  • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
  • F16C2226/00—Joining parts; Fastening; Assembling or mounting parts
  • F16C2226/50—Positive connections
  • F16C2226/52—Positive connections with plastic deformation, e.g. caulking or staking
• • 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
  • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
  • F16C2240/00—Specified values or numerical ranges of parameters; Relations between them
  • F16C2240/30—Angles, e.g. inclinations
• • 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
  • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
  • F16C2326/00—Articles relating to transporting
  • F16C2326/01—Parts of vehicles in general
  • F16C2326/02—Wheel hubs or castors

Definitions

• the present invention relates to a crimping method, a method for manufacturing a hub unit bearing, a method for manufacturing a vehicle, a method for manufacturing a mechanical device, and a crimping device.
• a hub unit bearing is known as an example of a crimped assembly in which a first member and a second member are axially combined.
• the hub unit bearing rotatably supports the wheels and braking rotors of an automobile relative to the suspension system.
• a hub unit bearing comprises an outer ring having a double-row outer ring raceway on its inner circumferential surface, a hub having a double-row inner ring raceway on its outer circumferential surface, and a plurality of rolling elements arranged to roll freely between the double-row outer ring raceway and the double-row inner ring raceway.
• the hub comprises an inner ring and a hub body (hub wheel).
• the inner ring is press-fit onto a mating shaft portion provided on the axially inner portion of the hub body (inner side of the vehicle width when the hub unit bearing is installed on the vehicle), with its axially outer end face (outer side of the vehicle width when the hub unit bearing is installed on the vehicle) abutting against a stepped surface provided on the axially middle portion of the hub body and facing axially inward.
• the axially inner end face of the inner ring is pressed against by a crimped portion formed by plastically deforming radially outward a cylindrical portion of the mating shaft portion that protrudes axially inward beyond the axially inner end face of the inner ring. This securely connects the inner ring and the hub body and applies preload to the rolling elements.
• JP 2015-77616 A describes an oscillation clamping method for joining a hub body and an inner ring.
• the method involves pressing a die (metal mold) supported so that it can rotate about a central axis that is inclined relative to a reference axis that is coaxial with the central axis of the hub body against a cylindrical portion, while rotating the die about the reference axis to plastically deform the cylindrical portion radially outward to form a crimped portion.
• the oscillation angle which is the inclination angle of the central axis of the die relative to the reference axis, is set to between 15° and 30°, thereby keeping the processing load low.
• aspects of the present invention aim to provide a crimping method, a method for manufacturing a hub unit bearing, a method for manufacturing a vehicle, a method for manufacturing a mechanical device, and a crimping processing device that are advantageous for reducing manufacturing costs and/or improving product quality.
• a crimping method includes the steps of: setting a workpiece, in which a first member and a second member are axially combined, along a reference axis; and forming a crimped portion in the first member, the steps including: deforming the first member using a first relative rotation about the reference axis between a first pressing die and the workpiece; and further deforming the first member using a second relative rotation about the reference axis between a second pressing die and the workpiece.
• the central axis of the first pressing die is inclined with respect to the reference axis at a first tilt angle
• the central axis of the second pressing die is inclined with respect to the reference axis at a second tilt angle different from the first tilt angle
• a method for manufacturing a vehicle includes manufacturing a hub unit bearing using the above-described manufacturing method, and assembling a vehicle using the hub unit bearing.
• a method for manufacturing a mechanical device includes manufacturing a crimped assembly using the above-described crimping joining method, and assembling a mechanical device using the crimped assembly.
• a crimping device in another aspect of the present invention, includes a reference axis, a holder for supporting a workpiece, a stamping die having a central axis, a first mechanism for performing relative rotation around the reference axis between the workpiece and the stamping die with the central axis tilted relative to the reference axis, and a second mechanism for changing the tilt angle of the central axis relative to the reference axis.
• the central axis of the stamping die is tilted relative to the reference axis at a first tilt angle.
• the central axis of the stamping die is tilted relative to the reference axis at a second tilt angle different from the first tilt angle.
• This aspect of the present invention is advantageous in reducing manufacturing costs and/or improving product quality.
• FIG. 1 is a cross-sectional view showing an example of a wheel drive unit equipped with a hub unit bearing.
• FIG. 2 is a cross-sectional view showing a schematic diagram of the crimping device.
• Part (A) of FIG. 3 is a cross-sectional view showing a part of the caulking device, and part (B) is a view showing the part (A) with a different swing angle.
• Parts (A) and (B) of FIG. 4 are diagrams for explaining a mechanism for changing the swing angle, part (a) is a diagram seen from the axial direction, and part (b) is a perspective view.
• Parts (A) to (E) of FIG. 5 are schematic cross-sectional views showing the crimping joining method in the order of steps.
• FIG. 6 is a partial schematic diagram of a vehicle equipped with a hub unit bearing.
• the crimping method involves fitting a cylindrical second metal member onto a first metal member having a cylindrical portion at one axial end. The axial end of the cylindrical portion is then plastically deformed to form a crimped portion. The first and second members are joined by preventing the second member from displacing axially toward one side relative to the first member.
• the crimping method and crimping apparatus are widely applicable to the manufacture of machinery, vehicles, or components thereof, which include two metal members joined by a crimped portion.
• the crimping method and crimping device are applied to the manufacture of hub unit bearings that form a vehicle.
• the crimping method and crimping device are applied to the manufacture of hub unit bearings that form a vehicle.
• the crimping device 38 further includes a support table (support portion, holder) 60 that supports the workpiece, the hub unit bearing 2, so that it can move relative to the die 39 in the axial direction of the reference axis C.
• An arrangement process is also carried out in which the first member, the hub body 17a, is arranged so that the central axis O of the hub body 17a is coaxial with the reference axis C.
• the hub unit bearing 2 is supported on the support base 60 without any radial play, with its central axis O aligned with the reference axis C, and with the axially inner side facing upward and the axially outer side facing downward.
• the processing load in the first forming step can be, for example, 10 kN or more and 200 kN or less, preferably 30 kN or more and 150 kN or less, and more preferably 50 kN or more and 150 kN or less.
• the above numerical values are merely examples and are not limiting.
• the first forming process ends and the next step, the second forming process, begins.
• the timing to end the first forming step can be determined by any means.
• the timing to end the first forming step can be determined based on the relationship, determined in advance through experiments, between the amount of plastic deformation of the cylindrical portion 37, the elapsed time since the start of processing, and the current value of the electric motor 81 that rotates the pressing die 39 around the reference axis C.
• the spindle drive mechanism 41 stops rotating the press die 39 around the reference axis C.
• the support table 60 is lowered, and as shown in FIG. 5C, the machining surface 42 of the press die 39 is separated from the cylindrical portion 37 of the hub body 17a.
• the swing angle changing actuator 47 of the press die support mechanism 40 rotates the press die support block 45 around the swing angle changing axis O45 , thereby changing the swing angle ⁇ to the predetermined second angle ⁇ 2 (see FIG. 5D).
• a step of temporarily separating the press die 39 from the workpiece 90 (hub body 17a) is provided between the first molding step (first relative rotation) and the second molding step (second relative rotation).
• the axial positions of the center (point of the first tilt angle) P1 of the first angle (first tilt angle) ⁇ 1 in the first molding process and the center (point of the second tilt angle) P2 of the second angle (second tilt angle) ⁇ 2 in the second molding process are set to be different from each other.
• the axial position of the hub unit bearing 2 relative to the pressing die 39 is adjusted so that the distance between the intersection P2 of the reference axis C and the rotation axis R and the end (second end) of the hub body 17a on the other axial side (axially outer side) at the start of the second molding step is greater than the distance between the intersection P1 of the reference axis C and the rotation axis R and the end (second end) of the hub body 17a on the other axial side at the end of the first molding step.
• the center (point of the second tilt angle) of the second angle (second tilt angle) ⁇ 2 is located axially outward compared to the center (point of the second tilt angle) of the first angle (first tilt angle) ⁇ 1 , near the end (near the first end) of the workpiece 90 (hub body 17a) where the crimped portion is provided.
• the distance along the axial direction between the center (second tilt angle point) P2 of the second angle (second tilt angle) ⁇ 2 and the second end portion is greater than the distance along the axial direction between the center (first tilt angle point) P1 of the first angle (first tilt angle) ⁇ 1 and the second end portion in the first molding step (FIG. 5(D)).
• the axial position of the hub unit bearing 2 with respect to the pressing die 39 is adjusted so that the intersection P2 of the reference axis C and the rotation axis R at the start of the second molding step is located to one axial side (upper side in this example) of the intersection P1 of the reference axis C and the rotation axis R at the end of the first molding step.
• the processing load in the second forming step can be the same as or different from the processing load in the first forming step.
• the processing load in the second forming step can be, for example, 10 kN or more and 300 kN or less, preferably 50 kN or more and 300 kN or less, and more preferably 100 kN or more and 300 kN or less.
• the above numerical values are merely examples and are not limiting.
• the load point (load area) where a load is applied from the die 39 to the hub body (first member) 17a changes circumferentially on the cylindrical portion 37 (crimped portion 19) of the hub body 17a (orbital forging).
• orbital forging applies a load to the hub body 17a that includes a load component that acts radially outward, particularly using the radially inner region of the machined surface portion 42 of the die 39, and the position where the load is applied moves circumferentially. Part of the hub body 17a deforms radially outward.
• the load-bearing point (load-bearing area) where the load is applied from the die 39 to the hub body (first member) 17a also changes circumferentially on the hub body 17a (orbital forging).
• orbital forging uses the radially outer region of the machined surface portion 42 of the die 39 in particular, and a load including a load component directed radially inward is applied to the radially outer portion of the hub body 17a, and the position at which the load is applied moves circumferentially. Part of the hub body 17a is deformed radially inward.
• At least one of the movement, position, and posture of the die 39 differs between the first molding process and the second molding process.
• the axial position and/or direction of the load differs between the first loaded point (first loaded area) in the first relative rotation and the second loaded point (second loaded area) in the second relative rotation.
• the shortest axial distance between the loaded point and the second end in the second molding process (second relative rotation) is shorter than the shortest axial distance between the loaded point and the second end in the first molding process (first relative rotation).
• the cylindrical portion 37 is plastically deformed to form the crimped portion 19, thereby joining the hub body 17 and the inner ring 16, and then the hub-side face spline 12 is formed on the axially inner end face of the crimped portion 19.
• the method for forming the hub-side face spline 12 is not particularly limited.
• the hub-side face spline 12 can be formed by a typical forging press process, in which a processed portion consisting of alternating concave and convex portions arranged in the circumferential direction is pressed against the crimp portion 19.
• the hub-side face spline 12 can be formed by orbital forging, in which a forming die supported so that it can rotate about a central axis inclined relative to the central axis O of the hub unit bearing 2 is pressed against the crimp portion 19 while rotating about the central axis O of the hub unit bearing 2.
• the oscillation angle ⁇ of the die 39 is set to a relatively large second angle ⁇ 2 , and the cylindrical portion 37 is subjected to an oscillation and crimping process using the die 39 to further plastically deform the crimped portion 19.
• FIG. 6 is a partial schematic diagram of a vehicle 200 equipped with a hub unit bearing (bearing, bearing device) 151.
• the above-mentioned bearing can be used as a hub unit bearing for both driving wheels and driven wheels.
• the hub unit bearing 151 is for a driving wheel and includes an outer ring 152, a hub 153, and multiple rolling elements 156.
• the outer ring 152 is fixed to a knuckle 201 of the suspension device using bolts or the like.
• the wheel 202 (and braking rotor 22) is fixed to a flange (rotating flange) 153A provided on the hub 153 using bolts or the like.
• the vehicle 200 can also have a support structure similar to that described above for the hub unit bearing 151 for the driven wheels.
• a crimping method includes the steps of setting a workpiece, in which a first member and a second member are axially assembled, along a reference axis, and forming a crimped portion in the first member.
• the step of forming the crimped portion includes deforming the first member using a first relative rotation about the reference axis between a first press die and the workpiece, and further deforming the first member using a second relative rotation about the reference axis between a second press die and the workpiece.
• the central axis of the first press die is tilted with respect to the reference axis at a first tilt angle.
• the central axis of the second press die is tilted with respect to the reference axis at a second tilt angle different from the first tilt angle.
• the center of the second inclination angle is located outward in the axial direction compared to the center of the first inclination angle, near the end of the first member where the crimped portion is provided.
• the first and second press molds may be the same press mold, or may be different press molds.
• the first and second press molds are the same press mold, and the method further includes a step of temporarily separating the first press mold from the workpiece between the first relative rotation and the second relative rotation.
• a method for manufacturing a hub unit bearing uses the above-mentioned crimping method to manufacture a hub unit bearing.
• a vehicle manufacturing method includes manufacturing a hub unit bearing using the above-described manufacturing method, and assembling a vehicle using the hub unit bearing.
• the crimping device includes a reference axis, a holder for supporting a workpiece, a stamping die having a central axis, a first mechanism for performing relative rotation around the reference axis between the workpiece and the stamping die with the central axis tilted relative to the reference axis, and a second mechanism for changing the tilt angle of the central axis relative to the reference axis.
• the central axis of the stamping die is tilted relative to the reference axis at a first tilt angle.
• the central axis of the stamping die is tilted relative to the reference axis at a second tilt angle different from the first tilt angle.
• the axial positions of the center of the first tilt angle and the center of the second tilt angle are different from each other.
• the first mechanism has a first drive source
• the second mechanism has a second drive source different from the first drive source
• the press mold includes a first press mold used for the first relative rotation and a second press mold used for the second relative rotation, and the first press mold and the second press mold may be the same press mold or may be separate press molds.
• a crimping method in another aspect, includes an outer fitting process in which a cylindrical second member is fitted onto a first member having a cylindrical portion at one axial end, a first molding process, and a second molding process.
• a first stamping die which is supported so as to be rotatable about a first rotation axis that is its central axis, is pressed against the one axial end of the cylindrical portion with the first rotation axis tilted at a predetermined first angle with respect to the central axis of the first member, while rotating about the central axis of the first member, thereby plastically deforming the cylindrical portion.
• a second stamping die which is supported so as to be rotatable about a second rotation axis that is its central axis, is pressed against the one axial end of the cylindrical portion with the second rotation axis tilted at a predetermined second angle that is larger than the first angle with respect to the central axis of the first member, while rotating about the central axis of the first member, thereby further plastically deforming the cylindrical portion, thereby forming a crimped portion that presses against the one axial end face of the second member.
• the first pressing mold and the second pressing mold can be the same.
• the first molding process and the second molding process can be performed using the same device.
• the crimping method in the above aspect can further include, after the second molding step, a spline forming step in which a face spline is formed on one axial end face of the crimped portion, with recesses and protrusions arranged alternately in the circumferential direction.
• the first angle can be set to be equal to or greater than 3° and less than 10°
• the second angle can be set to be equal to or greater than 10° and less than 30°.
• the hub comprises an inner ring having at least the axially innermost inner ring raceway of the multiple inner ring raceways on its outer peripheral surface, a mating shaft portion onto which the inner ring is fitted, and a hub body having a crimping portion at its axially inner end portion that presses against the axially inner end face of the inner ring.
• the outer ring can be rotated relative to the hub body and the inner ring throughout the entire process of forming the crimped portion.
• the vehicle that is the subject of the vehicle manufacturing method is equipped with a hub unit bearing.
• the hub unit bearing is manufactured using the hub unit bearing manufacturing method of one aspect of the present disclosure.
• the crimping device comprises a die, a die support mechanism that supports the die so that the tilt angle of the rotation axis, which is the central axis of the die, relative to a reference axis can be adjusted and so that the die can rotate around the rotation axis, and a spindle drive mechanism that drives the die support mechanism to rotate around the reference axis.
• the crimping device in the above aspect may further include a support table that supports the workpiece so that it can move relative to the die in the axial direction of the reference axis.
• the die support mechanism can include a die support block having a die support recess formed in a direction inclined relative to the reference axis and supported so as to be rotatable about a swing angle change axis arranged parallel to the reference axis, an aligning bearing arranged between the die and the die support recess, and a swing angle change actuator that rotates the die support block about the swing angle change axis.
• the spindle drive mechanism can include a spindle that is formed in the axial direction of the reference axis at a location radially offset from the reference axis, has a block holding recess inside which the die support block is supported, and is supported so as to be rotatable about the reference axis, and an electric motor that rotates the spindle.

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• Engineering & Computer Science (AREA)
• General Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Rolling Contact Bearings (AREA)

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• 2024
  • 2024-11-21 WO PCT/JP2024/041358 patent/WO2025210955A1/ja active Pending
  • 2024-11-21 JP JP2025513614A patent/JPWO2025210955A1/ja active Pending
  • 2024-11-21 EP EP24875758.5A patent/EP4656308A4/en active Pending

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