The disclosure of Japanese Patent Application No. 2010-192413 filed on Aug. 30, 2010 including the specification, drawings and abstract, is incorporated herein by reference in its entirety.
1. Field of the Invention
The invention relates to a manufacturing method for a vehicle hub unit in which a member that constitutes an inner ring is fixed by clinching to an end portion of a hub spindle of a hub wheel to which a wheel is fitted.
2. Description of Related Art
A hub unit is used to support a wheel of an automobile such that the wheel is rotatable with respect to a suspension.
A hub unit 51 shown in
Rotational driving force of a drive shaft 60 is transmitted to the hub unit 51 via a constant velocity joint 59. As one method of transmitting the rotational driving force, there is known a method in which, as shown in
In the hub units described in Published Japanese Translation of PCT Application No. 2008-536737 and Japanese Patent Application Publication No. 2008-174178, rotational driving force is transmitted to the hub unit via a constant velocity joint due to the mesh of the teeth that extend in a direction substantially perpendicular to a rotary shaft.
A manufacturing method for the above-described spline tooth portion 62 will be described below with reference to
However, an end surface of the existing punch 142 has a conical shape of which the center just slightly protrudes. Therefore, the material of the hub spindle end portion may be deformed toward the radial center of the hub spindle 52 as the oscillating clinching proceeds. If plastic deformation toward the radial center of the hub spindle 52 becomes significant, a portion 61a formed due to deformation toward the radial center of the hub spindle 52 may contact the constant velocity joint when the constant velocity joint is fitted to the hub unit.
It is an object of the invention to provide a manufacturing method for a vehicle hub unit, according to which deformation of an end portion of a hub spindle toward the radial center of the hub spindle during oscillating clinching is prevented to thereby make it possible to avoid contact between the end portion and a constant velocity joint when the constant velocity joint is fitted to the hub unit.
An aspect of the invention relates to a manufacturing method for a vehicle hub unit in which a hub wheel is arranged radially inward of an outer ring via rolling elements, an inner ring member is fixed to an end portion of a hub spindle of the hub wheel by clinching, a spline tooth portion that meshes with a tooth portion of a constant velocity joint that transmits driving force to the hub unit is formed at a clinched portion of the hub spindle, and a protruding portion is formed at a radially inner side portion of a bottom of the spline tooth portion. The clinched portion is formed by plastically deforming a cylindrical end portion of the hub spindle outward with a clinching tool. The clinching tool includes a punch that is configured to be inserted into the cylindrical end portion and that has a guide portion that is configured to contact the cylindrical end portion with a predetermined inclination angle with respect to an inner peripheral surface of the end portion, and an oscillating spindle to which the punch is non-rotatably attached. The guide portion is formed in a projecting shape so as to project from a center portion of one end surface of the punch. A tooth profile for plastically machining the spline tooth portion is formed at the one end surface of the punch, at a portion radially outward of a base of the guide portion. The guide portion of the punch is inserted into the end portion of the hub spindle, the punch is pressed against the end portion of the hub spindle with predetermined pressing force, and a spindle that is coaxial with the hub spindle is rotated to oscillate the clinching tool, so that the clinched portion and the spline tooth portion are formed at the same time through plastic deformation while plastic deformation of the end portion of the hub spindle toward a radial center of the hub spindle is suppressed by the guide portion.
Features, advantages, and technical and industrial significance of exemplary embodiments of the invention will be described below with reference to the accompanying drawings, in which like numerals denote like elements, and wherein:
Hereinafter, a manufacturing method for a vehicle hub unit according to an embodiment of the invention will be described in detail with reference to the accompanying drawings.
First, the configuration of the vehicle hub unit manufactured by the manufacturing method according to the embodiment of the invention will be described.
The vehicle hub unit 1 supports a wheel of an automobile such that the wheel is rotatable with respect to a suspension. The vehicle hub unit 1 includes a hub wheel 3, an outer ring 5 and a plurality of rolling elements 6. The hub wheel 3 has a cylindrical hub spindle 2. An inner ring member 4 is fixed to one end (right end portion in
A flange portion 7 is formed at the end portion (left end portion in
The hub spindle 2 is a single-piece member that has a large-diameter portion 9 and a small-diameter portion 11. The large-diameter portion 9 is formed at a position near the flange portion 7. The small-diameter portion 11 is smaller in diameter than the large-diameter portion 9, and is formed so as to be contiguous with the large-diameter portion 9 via a step 10. The inner ring raceway 2a is formed in the outer peripheral surface of the large-diameter portion 9. The inner ring raceway 2a corresponds to the outer ring raceway 5a of the outer ring 5.
The inner ring member 4 is fitted onto the outer peripheral surface of the small-diameter portion 11 of the hub spindle 2, and then an end portion of the small-diameter portion 11 is clinched to form a clinched portion 12, as will be described later. In this way, the inner ring member 4 is fixed between the step 10 and the clinched portion 12.
Driving force of a drive shaft 31 is transmitted to the hub unit 1 via a constant velocity joint 30. The constant velocity joint 30 shown in the drawing is a Birfield constant velocity joint. The constant velocity joint 30 includes an inner ring 32, a plurality of balls 34 and a cage 35. The inner ring 32 is joined to one end of the drive shaft 31. The balls 34 are arranged between the inner ring 32 and an outer ring 33 that is arranged radially outward of the inner ring 32. The cage 35 retains the balls 34.
The outer ring 33 of the constant velocity joint 30 has a bowl-shaped outer ring cylindrical portion 33a and an outer ring shaft portion 33b. The outer ring shaft portion 33b extends from a center portion of an end surface of the outer ring cylindrical portion 33a. The outer ring shaft portion 33b has a hole 36 that extends in the axial direction. The inner peripheral surface of the outer ring shaft portion 33b, which defines the hole 36, has an internal thread. The hub unit 1 is connected to the constant velocity joint 30 by a cap bolt 38 that has an external thread 37 at its end portion.
As shown in
The number of teeth 13a of the spline tooth portion 13 is 37, a protruding portion 15 is formed at each bottom 13b between the consecutive teeth 13a. Each protruding portion 15 protrudes toward the tooth portion 14 of the outer ring cylindrical portion 33a that faces the spline tooth portion 13. Each protruding portion 15 is formed at a radially inner portion of the bottom 13b of the spline tooth portion 13. More specifically, each protruding portion 15 is formed at the bottom 13b at a portion substantially radially inward of a meshing portion 16 (hatched portion in
A predetermined clearance C1 is left between each bottom 13b of the spline tooth portion 13, including the surface of the protruding portion 15, and a top surface 14c of the tooth 14a of the tooth portion 14 of the outer ring cylindrical portion 33a, which faces the bottom 13b. On the other hand, a predetermined clearance C2 is left between a top surface 13c of each tooth 13a of the spline tooth portion 13 and a bottom 14b of the tooth portion 14 of the outer ring cylindrical portion 33a, which faces the top surface 13c.
Both the spline tooth portion 13 and the tooth portion 14 of the outer ring cylindrical portion 33a are formed by closed die forging. The predetermined clearances C1 and C2 are set such that tolerances in closed die forging are absorbed so as not to cause contact between the teeth when the constant velocity joint 30 is fitted to the hub unit 1. Although the clearances C1 and C2 vary depending on the accuracy of closed die forging, the clearances C1 and C2 are usually approximately 0.5 to 1 mm.
A manufacturing method for the vehicle hub unit will be described below. The above-described spline tooth portion 13 is formed together with the clinched portion 12 at the same time by fitting the inner ring member 4 onto the outer peripheral surface of the small-diameter portion 11 of the hub spindle 2 and then subjecting the end portion of the small-diameter portion 11 to closed die forging.
Closed die forging may be performed using a clinching tool.
As shown in
The guide portion 41 of the punch 42 has a projecting shape that projects from the center portion of one end surface of the punch 42. A tooth profile 42a is formed in the one end surface of the punch 42, at a portion radially outward of the base of the guide portion 41. The tooth profile 42a is used to plastically form the spline tooth portion 13. A recess 44 having a shape corresponding to each protruding portion 15 of the spline tooth portion 13 is formed at a radially inner side portion of each protruding portion 42b of the punch 42, which corresponds to the bottom of the spline tooth portion 13. During closed die forging, the recesses 44 are used to form the protruding portions 15 of the spline tooth portion 13.
When the clinched portion 12 and the spline tooth portion 13 are formed, first, the clinching tool 40 is inserted into the small-diameter portion 11 of the hub spindle 2 of the hub wheel 3. Subsequently, the punch 42 of the clinching tool 40 is pressed against the end portion of the small-diameter portion 11 with predetermined pressing force, and a spindle (not shown) that is coaxial with the hub spindle 2 is rotated to oscillate the clinching tool 40. Through the oscillating clinching, the small-diameter portion 11 is plastically deformed radially outward and the clinched portion 12 is formed, and, at the same time, the spline tooth portion 13 is formed at the end surface of the clinched portion 12 by the tooth profile of the punch 42.
In the embodiment of the invention, the punch 42 has the guide portion 41. The guide portion 41 is configured to contact the end portion of the small-diameter portion 11 with a predetermined angle with respect to the inner peripheral surface of the small-diameter portion 11 of the hub spindle 2. Therefore, plastic deformation of the small-diameter portion 11 toward the radial center of the sub spindle 2 during oscillating clinching is suppressed. Accordingly, the predetermined protruding portions 15 are accurately formed at a radially inner side portion of the spline tooth portion 13. Thus, it is possible to avoid contact between the hub wheel 3 and the constant velocity joint 30 when the constant velocity joint 30 is fitted to the hub unit 1.
In addition, in the present embodiment, an annular restraining member 70 is arranged radially outward of the inner ring member 4. The restraining member 70 is used to prevent the inner ring member 4 from deforming radially outward due to pressure applied from the punch 42 during oscillating clinching. As shown in
When the restraining member 70 is used, the radially outer side portion of the inner ring member 4 close to the inner ring raceway 4a is restrained by the restraining member 70. Therefore, deformation of the inner ring member 4 during clinching is suppressed, and it is possible to prevent occurrence of indentation in the inner ring raceway 4a.
The protrusion height of the annular protruding portion 72 in the axial direction is adjusted to such a height that the inner peripheral surface of the annular protruding portion 72 contacts a portion of the outer peripheral surface of the inner ring member 4, on which the seal member 21 will be arranged. If the protrusion height of the annular protruding portion 72 in the axial direction is adjusted in this way, even when an annular recess 4d is formed in the inner-side end portion of the inner ring member 4 in order to fit an annular dust cover 80 (see
The protrusion height of the annular protruding portion 72 in the axial direction is set to such a height that a distance of approximately 0.5 mm is ensured between the end surface of the annular protruding portion 72 and an inner ring shoulder portion 4c that is the boundary between the inner ring raceway 4a and outer peripheral surface 4b of the inner ring member 4. Thus, it is possible to prevent contact between the end surface of the annular protruding portion 72 and the rolling elements 6 during oscillating clinching.
When the end portion of the small-diameter portion 11 of the hub spindle 2 is clinched by oscillating clinching and the spline tooth portion 13 is formed at the clinched portion 12, lubricant, for example, lubricating oil, is usually used in order to extend the service life of the punch 42 and to stabilize the accuracy of teeth formed. In this case, lubricating oil may be sprayed onto a lubrication portion, that is, the end portion of the small-diameter portion 11 of the hub spindle 2. However, when the lubricating oil is sprayed, there is a problem that it is difficult to stabilize the amount of applied lubricating oil and, in addition, lubricating oil adheres to portions other than the portion that need lubrication. Then, there is another problem that the number of cleanup works for equipment increases due to the lubricating oil scattering or adhering to the portions other than the portion that needs lubrication.
In contrast to this, in order to spray lubricating oil only to portions that need lubrication, an additional device, such as masking, is required. Therefore, there is yet another problem that not only the equipment becomes complex but also the working process becomes complicated.
Then, in the present embodiment, as shown in
The applicator 90 is formed of a first applicator 93 and a second applicator 94. The first applicator 93 is immersed in lubricating oil 92 stored in a container 91. The second applicator 94 contacts the first applicator 93 to absorb the lubricating oil.
The first applicator 93 is formed of a disc-shaped body 93a and a cylindrical absorbing portion 93b. The body 93a has a hole at its center. The absorbing portion 93b is inserted into the hole of the body 93a. The body 93a of the first applicator 93 is arranged on the upper surface of a perforated partition panel 91a of the container 91. The absorbing portion 93b extends through the hole 91b of the perforated partition panel 91a, and is immersed in the lubricating oil 92 in the container 91. The lubricating oil 92 is absorbed by the absorbing portion 93b and spreads all around the body 93a. In this case, because the absorbing portion 93b has a cylindrical shape, it is possible to ensure a large contact area at which the absorbing portion 93b contacts the lubricating oil 92 in the container 91, and the body 93a efficiently absorbs the lubricating oil 92.
When the second applicator 94 is brought into contact with the body 93a, the second applicator 94 absorbs an appropriate amount of lubricating oil. When the second applicator 94 that has absorbed the appropriate amount of lubricating oil is brought into contact with the end portion of the small-diameter portion 11 of the hub spindle 2 in a stamping manner, an optimal amount of lubricating oil is uniformly applied to only forged portions. The second applicator 94 is moved by forming the hole at the center of the second applicator 94, inserting a columnar engaging portion (not shown) of a transferring mechanism into the hole, and moving the transferring mechanism by appropriate driving means.
Note that the stamping application method using the above-described applicator 90 made of spongy porous material is not limited to the case where a spline tooth portion is machined by oscillating clinching, and the application method may also be applied to another general oscillating clinching in which a spline tooth portion is not formed.
The invention is not limited to the above-described embodiment, and various modifications and changes may be made within the scope of the appended claims. For example, in the above-described embodiment, the sectional shape of each protruding portion is a wavy shape. Alternatively, another sectional shape, such as a semi-circular shape and a trapezoidal shape, may be employed. In addition, in the above-described embodiment, there is employed a third-generation structure in which an inner ring raceway is directly formed in the outer periphery of the hub spindle. Alternatively, a first-generation or second-generation structure in which a pair of inner rings is press-fitted onto a hub spindle may be employed. In addition, in the above-described embodiment, the peripheral surface (in the sectional view shown in
In the manufacturing method according to the invention, the guide portion that projects from the center portion of one end surface of the punch suppresses plastic deformation of the hub spindle end portion toward radial center of the hub spindle during oscillating clinching. Therefore, it is possible to avoid contact between the hub wheel and the constant velocity joint when the constant velocity joint is fitted to the hub unit.
Number | Date | Country | Kind |
---|---|---|---|
2010-192413 | Aug 2010 | JP | national |