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JP5466419B2 - Integrated axle housing for automobile and method for manufacturing the same - Google Patents

Integrated axle housing for automobile and method for manufacturing the same Download PDF

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JP5466419B2
JP5466419B2 JP2009091213A JP2009091213A JP5466419B2 JP 5466419 B2 JP5466419 B2 JP 5466419B2 JP 2009091213 A JP2009091213 A JP 2009091213A JP 2009091213 A JP2009091213 A JP 2009091213A JP 5466419 B2 JP5466419 B2 JP 5466419B2
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diameter
axle housing
intermediate material
diameter portion
pipe material
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JP2010241229A (en
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幸孝 国本
晃次 須田
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株式会社 クニテック
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    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00Road transport of goods or passengers
    • Y02T10/80Technologies aiming to reduce greenhouse gasses emissions common to all road transportation technologies
    • Y02T10/86Optimisation of rolling resistance, e.g. weight reduction 

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Description

本発明は、直管状のパイプ素材を原材料とし、このパイプ素材を塑性加工することにより形成される、全体として一体的な管形状の車両用一体型アクスルハウジング及びその製造方法に関するものである。   The present invention relates to a vehicle-integrated axle housing for a vehicle which is formed as a whole by using a straight pipe material as a raw material and plastically processing the pipe material, and a method for manufacturing the same.

上記車両用アクスルハウジング、及びその製造方法には、従来、下記特許文献1〜3に示されるものがある。これらの公報における製造方法は、まず金属板をプレス加工して多数の部分品を製造し、次にこれらの部分品を溶接により接合してアクスルケースとして完成させ、その両端に車輪を支持する軸受部を接合すると共に、中央部に差動装置が収容される膨出部を接合してアクスルハウジングを完成させている。そして、このように構成されたアクスルハウジングが、コイルスプリング又はリーフスプリング等を介して車体に懸架される。   Conventionally, the vehicle axle housing and the manufacturing method thereof are disclosed in Patent Documents 1 to 3 below. The manufacturing methods in these publications are: first, a metal plate is pressed to produce a number of parts, then these parts are joined together by welding to complete an axle case, and bearings that support wheels on both ends thereof. The axle housing is completed by joining the bulging part in which the differential device is accommodated in the center part. And the axle housing comprised in this way is suspended by the vehicle body via a coil spring or a leaf spring.

特開2005−132249号公報JP 2005-132249 A 特開平10−329503号公報Japanese Patent Laid-Open No. 10-329503 特開平08−187535号公報Japanese Patent Laid-Open No. 08-187535

しかしながら、このように従来の車両用アクスルハウジングは、多数の部品から構成されていたため、部品管理や物流コストが高く、しかもこれら多くの部品がプレス加工により製造されてから溶接により組み立てられていたため、トータル加工時間が多大であり、製造コストが高く、その割に製品の信頼性を確保することが困難であった。   However, since the conventional vehicle axle housing was composed of a large number of parts, parts management and logistics costs were high, and many of these parts were manufactured by pressing and then assembled by welding. The total processing time is enormous, the manufacturing cost is high, and it is difficult to ensure the reliability of the product.

特に溶接工程では、溶接長が長くなるために製品に歪み等の製造欠陥が発生しやすく、このような製造欠陥を防止するには熟練工の存在が不可欠であり、しかも溶接の品質が極めて重要な項目であるため、高い信頼性を確保するために最高ランクの品質管理及び過度の安全設計が行われ、このような点が製造コストアップをさらに助長させていた。   Especially in the welding process, because the weld length is long, manufacturing defects such as distortion are likely to occur in the product. The existence of skilled workers is indispensable to prevent such manufacturing defects, and the quality of welding is extremely important. Therefore, in order to ensure high reliability, the highest-ranking quality control and excessive safety design were performed, and this point further increased the manufacturing cost.

安全設計を向上させるということは、溶接部における強度低下を防ぐために各部品の肉厚を予め大きく設定することでもあり、その結果、アクスルハウジングの重量が増加して車両のばね下重量が重くなり、操縦安定性や乗り心地の低下を招いてしまうという懸念があった。   Improving the safety design also means setting the thickness of each part to be large in advance in order to prevent a decrease in strength at the welded part. As a result, the weight of the axle housing increases and the unsprung weight of the vehicle increases. There was a concern that steering stability and ride comfort would be reduced.

本発明は、このような事情に鑑みてなされたものであり、構成部品点数及び溶接部位を削減して製造を容易にし、品質を低下させることなく製造コストダウンと小型軽量化を図り、且つ差動装置が収容される膨出部の強度を高く確保することができる自動車用一体型アクスルハウジング及びその製造方法を提供することを目的とする。   The present invention has been made in view of such circumstances, and facilitates manufacture by reducing the number of component parts and welded parts, and achieves reduction in manufacturing cost and reduction in size and weight without degrading quality. It is an object of the present invention to provide an integrated axle housing for automobiles and a method for manufacturing the same that can ensure high strength of a bulging portion in which a moving device is accommodated.

かかる課題を解決するために、本発明の請求項1に係る発明は、差動装置が収容される膨出部と、該膨出部から車幅方向両側に延びて内部にアクスル軸が軸支されるアクスルケースとを、閉断面を有する1本のパイプ素材を塑性加工することにより一体に形成した自動車用一体型アクスルハウジングであって、前記膨出部は、前記差動装置が挿入される開口部を有する補強リング取付面と、この補強リング取付面に対向する膨出面とを有し、前記開口部に補強リングを介して前記差動装置のデフキャリアを固定し、前記補強リングは前記開口部の周囲に固着し、前記補強リングには、前記補強リング取付面と前記膨出面との間を連結する連結補強部材を設けた自動車用一体型アクスルハウジングとしたことを特徴とする。 In order to solve such a problem, the invention according to claim 1 of the present invention includes a bulging portion in which the differential gear is accommodated, and an axle shaft that supports the axle shaft extending from the bulging portion to both sides in the vehicle width direction. An automobile integrated axle housing in which an axle case is integrally formed by plastic processing a single pipe material having a closed cross section , and the bulging portion is inserted with the differential device. A reinforcing ring mounting surface having an opening, and a bulging surface facing the reinforcing ring mounting surface, and the differential carrier of the differential device is fixed to the opening through the reinforcing ring; It is characterized in that it is an automobile-integrated axle housing that is fixed to the periphery of the opening and is provided with a connecting reinforcing member that connects the reinforcing ring mounting surface and the bulging surface to the reinforcing ring .

請求項2に係る発明は、請求項1の構成に加え、前記補強リングは、前記開口部の周囲に固着される環状のリング本体を有し、該リング本体に前記連結補強部材が複数設けられ、前記補強リングの、前記連結補強部材が設けられている部分の間に雌ネジを形成し、前記差動装置を前記雌ネジにボルトで締結した自動車用一体型アクスルハウジングとしたことを特徴とする。 According to a second aspect of the present invention, in addition to the configuration of the first aspect, the reinforcing ring has an annular ring body fixed around the opening, and a plurality of the connecting reinforcing members are provided on the ring body. And an integrated axle housing for automobiles in which a female screw is formed between portions of the reinforcing ring provided with the connecting reinforcing member, and the differential is fastened to the female screw with a bolt. To do.

請求項3に係る発明は、請求項1又は2の構成に加え、前記連結補強部材をパイプ状且つ車体前後方向に沿うように形成し、この連結補強部材に、前記差動装置を前記補強リング取付面に締結するボルトを挿通し、このボルトにより前記差動装置と前記補強リングと前記膨出部とを共締めした自動車用一体型アクスルハウジングとしたことを特徴とする。 According to a third aspect of the present invention, in addition to the structure of the first or second aspect, the connection reinforcing member is formed in a pipe shape and along the longitudinal direction of the vehicle body, and the differential device is connected to the reinforcing ring on the connection reinforcing member. A bolt for fastening to the mounting surface is inserted, and the differential housing, the reinforcing ring, and the bulging portion are fastened together with the bolt to form an integrated axle housing for automobiles.

請求項4に係る発明は、請求項1乃至3のいずれかに記載の自動車用一体型アクスルハウジングの製造方法であって、所定の長さ、外径、肉厚を有するパイプ素材を塑性加工し、その中間部に位置する中央大径部と、該中央大径部の両側に位置し、該中央大径部の外径よりも小径な一対の小径部とを有する第1中間素材を形成する第1中間素材形成工程と、前記第1中間素材の前記中央大径部を径方向に押圧することにより扁平化させて扁平大径部とした第2中間素材を形成する第2中間素材形成工程と、前記第2中間素材の前記扁平大径部の前面に前記開口部を形成する開口部形成工程と、前記扁平大径部の、前記開口部に対向する後面を、前記開口部から離反する方向に突出成形することにより、前記扁平大径部を前記膨出部として成形する膨出部成形工程と、を備えてなる自動車用一体型アクスルハウジングの製造方法としたことを特徴とする。 An invention according to claim 4 is a method of manufacturing an automobile integrated axle housing according to any one of claims 1 to 3, wherein a pipe material having a predetermined length, outer diameter, and thickness is plastically processed. Forming a first intermediate material having a central large-diameter portion located in the intermediate portion and a pair of small-diameter portions located on both sides of the central large-diameter portion and having a diameter smaller than the outer diameter of the central large-diameter portion. A first intermediate material forming step and a second intermediate material forming step of forming a second intermediate material that is flattened by pressing the central large diameter portion of the first intermediate material in a radial direction to form a flat large diameter portion. And an opening forming step of forming the opening on the front surface of the flat large diameter portion of the second intermediate material, and a rear surface of the flat large diameter portion facing the opening is separated from the opening. Forming the flat large diameter part as the bulging part by projecting in the direction A bulged portion forming process that is characterized in that the method for manufacturing the automotive integral axle housing consisting comprise.

請求項5に係る発明は、請求項4の構成に加え、前記第1中間素材形成工程において、前記塑性加工をする前の前記パイプ素材の外径を前記中央大径部の外径に略一致させ、このパイプ素材を、その両端から中央部に向かって縮径し、中央部は縮径させないでおくことにより、前記第1中間素材の中央部に前記中央大径部を形成し、その両側に前記小径部を形成する自動車用一体型アクスルハウジングの製造方法としたことを特徴とする。 According to a fifth aspect of the present invention, in addition to the configuration of the fourth aspect, in the first intermediate material forming step, the outer diameter of the pipe material before the plastic working is substantially equal to the outer diameter of the central large diameter portion. The pipe material is reduced in diameter from both ends toward the central portion, and the central portion is not reduced in diameter so that the central large diameter portion is formed in the central portion of the first intermediate material. Further, the present invention is characterized in that a manufacturing method of an automobile integrated axle housing in which the small diameter portion is formed .

請求項6に係る発明は、請求項の構成に加え、前記第1中間素材形成工程において、前記塑性加工をする前の前記パイプ素材の外径を前記小径部の外径に略一致させ、このパイプ素材を、その一端から所定の長さまで拡径した後、この拡径した部分を前記一端から前記所定の長さよりも手前まで縮径することにより、前記第1中間素材の中央部に前記中央大径部を形成し、その両側に前記小径部を形成する自動車用一体型アクスルハウジングの製造方法としたことを特徴とする。 In addition to the configuration of claim 4 , the invention according to claim 6 makes the outer diameter of the pipe material before the plastic working substantially equal to the outer diameter of the small diameter portion in the first intermediate material forming step, After expanding the diameter of the pipe material from one end to a predetermined length, the diameter of the expanded portion is reduced from the one end to the front of the predetermined length. A method for manufacturing an automobile integrated axle housing in which a central large diameter portion is formed and the small diameter portions are formed on both sides thereof is characterized.

請求項7に係る発明は、請求項の構成に加え、前記第1中間素材形成工程において、前記塑性加工をする前の前記パイプ素材の外径を前記小径部の外径に略一致させ、該パイプ素材を金型の内部に設置し、該パイプ素材の内部に流体圧力を加えて前記金型内で所定の形状に膨張させることにより前記中央大径部を形成する自動車用一体型アクスルハウジングの製造方法としたことを特徴とする。 In addition to the configuration of claim 4 , the invention according to claim 7, in the first intermediate material forming step, substantially matches the outer diameter of the pipe material before the plastic working with the outer diameter of the small diameter portion, An automotive integrated axle housing that forms the central large diameter portion by installing the pipe material inside a mold and applying fluid pressure to the pipe material to expand the pipe material into a predetermined shape. The manufacturing method is characterized by the following.

請求項8に係る発明は、請求項の構成に加え、前記膨出部成形工程において、前記扁平大径部を、その後面側から所定の凹み形状を有する凹金型に設置し、前記扁平大径部の前面に形成した開口部から所定の凸形状を有する凸金型を突き込むことにより、前記扁平大径部の後面を前記凹金型の前記凹み形状内に陥没させて突出部を形成する自動車用一体型アクスルハウジングの製造方法としたことを特徴とする。 According to an eighth aspect of the invention, in addition to the configuration of the fourth aspect , in the bulging portion forming step, the flat large diameter portion is installed in a concave mold having a predetermined concave shape from the rear surface side, and the flat portion is formed. By projecting a convex mold having a predetermined convex shape from an opening formed in the front surface of the large diameter portion, the rear surface of the flat large diameter portion is recessed into the concave shape of the concave mold, and a protruding portion is formed. The manufacturing method of the integrated axle housing for automobiles to be formed is characterized.

請求項9に係る発明は、請求項1乃至3のいずれかに記載の自動車用一体型アクスルハウジングの製造方法であって、所定の長さ、外径、肉厚を有するパイプ素材を金型の内部に設置し、該パイプ素材の内部に流体圧力を加えて該パイプ素材を前記金型内で所定の形状に膨張させることにより、前記膨出部と前記アクスルケースとを同時に形成する自動車用一体型アクスルハウジングの製造方法としたことを特徴とする。 The invention according to claim 9 is the method for manufacturing an automobile integrated axle housing according to any one of claims 1 to 3, wherein a pipe material having a predetermined length, outer diameter, and wall thickness is made of a mold. A vehicle-use one that is installed inside and forms the bulging portion and the axle case at the same time by applying fluid pressure inside the pipe material to expand the pipe material into a predetermined shape in the mold. It is characterized by the manufacturing method of the body type axle housing.

請求項10に係る発明は、請求項1乃至3のいずれかに記載の自動車用一体型アクスルハウジングの製造方法であって、所定の長さ、外径、肉厚を有するパイプ素材を塑性加工し、その中間部に位置する中央大径部と、該中央大径部の両側に位置し、該中央大径部の外径よりも小径な一対の小径部とを有し、該小径部の両端部は閉塞され、且つその全体の体積が、完成した一体型アクスルハウジングの全体の体積に等しい中間素材を形成する中間素材形成工程と、前記中間素材の内部に非圧縮性の流体を一杯に封入する流体封入工程と、型閉じ時における成形室の内部容積が前記中間素材の全体の体積に等しい分割金型の、前記成形室に前記中間素材を設置する中間素材設置工程と、前記分割金型を型閉じすることにより、前記中間素材の前記中央大径部を扁平化すると同時に所定部分を突出させ、これにより前記中央大径部を前記膨出部として成形する膨出部成形工程と、前記膨出部の前面に前記開口部を形成する開口部形成工程と、を備えてなる自動車用一体型アクスルハウジングの製造方法としたことを特徴とする。 An invention according to claim 10 is a method for manufacturing an automobile integrated axle housing according to any one of claims 1 to 3, wherein a pipe material having a predetermined length, outer diameter, and wall thickness is plastically processed. A central large-diameter portion located in the middle portion thereof, and a pair of small-diameter portions located on both sides of the central large-diameter portion and having a smaller diameter than the outer diameter of the central large-diameter portion, both ends of the small-diameter portion The intermediate part is closed, and an intermediate material forming process for forming an intermediate material whose total volume is equal to the total volume of the completed integrated axle housing, and an incompressible fluid is filled inside the intermediate material. A fluid sealing step, a split mold having an inner volume of the molding chamber equal to the entire volume of the intermediate material when the mold is closed, an intermediate material installing step of installing the intermediate material in the molding chamber, and the split mold By closing the mold, before the intermediate material The central large-diameter portion is flattened and at the same time a predetermined portion is projected, thereby forming the bulge portion forming step with the central large-diameter portion as the bulge portion, and the opening is formed in front of the bulge portion. And an opening forming step . A method for manufacturing an integrated axle housing for automobiles is provided .

請求項1に係る発明によれば、構成部品点数及び溶接部位を削減して一体型アクスルハウジングの製造を容易にし、その品質を低下させることなく製造コストダウンと小型軽量化を図ることができる。また、補強リングに設けた連結補強部材により、差動装置が収容される膨出部の補強リング取付面と膨出面との間を堅固に連結し、膨出部の強度を高めることができる。 According to the first aspect of the present invention, it is possible to reduce the number of component parts and the welded parts to facilitate the manufacture of the integrated axle housing, and to reduce the manufacturing cost and reduce the size and weight without deteriorating the quality. In addition, the connecting reinforcing member provided on the reinforcing ring can firmly connect the reinforcing ring mounting surface and the bulging surface of the bulging portion in which the differential device is accommodated, thereby increasing the strength of the bulging portion.

請求項に係る発明によれば、膨出部の強度を高めると同時に、膨出部の内部における差動装置の配置自由度を向上させることができ、しかも差動装置を膨出部に堅固に固定することができる。 According to the second aspect of the present invention, the strength of the bulging portion can be increased, and at the same time, the degree of freedom of arrangement of the differential device within the bulging portion can be improved. Can be fixed to.

請求項に係る発明によれば、膨出部の強度を高めると同時に、差動装置を膨出部に締結するボルトと連結補強部材とを同軸状に配置してスペースを削減し、一体型アクスルハウジングの小型軽量化と、膨出部の内部における差動装置の配置自由度向上とを図ることができる。 According to the invention of claim 3 , the strength of the bulging portion is increased, and at the same time, the bolt and the connecting reinforcing member for fastening the differential device to the bulging portion are arranged coaxially to reduce the space, and the integrated type It is possible to reduce the size and weight of the axle housing and improve the degree of freedom of arrangement of the differential device inside the bulging portion.

請求項に係る発明によれば、1本のパイプ素材から一体型アクスルハウジングを容易に製造することができ、製造コストを安くすると共に、高い信頼性を確保することができる。 According to the invention which concerns on Claim 4 , an integral axle housing can be easily manufactured from one pipe raw material, and while reducing manufacturing cost, high reliability can be ensured.

請求項乃至に係る発明によれば、第1中間素材を容易に製造することができる。 According to the invention which concerns on Claims 5 thru | or 8 , a 1st intermediate material can be manufactured easily.

請求項及び10に係る発明によれば、一体型アクスルハウジングを容易に製造することができる。 According to the invention which concerns on Claim 9 and 10 , an integrated axle housing can be manufactured easily.

本発明の実施の形態1における一体型アクスルハウジングを備えた自動車の後輪懸架装置の一例を示す斜視図である。It is a perspective view which shows an example of the rear-wheel suspension apparatus of the motor vehicle provided with the integrated axle housing in Embodiment 1 of this invention. 同実施の形態1における一体型アクスルハウジングの正面図である。FIG. 2 is a front view of the integrated axle housing in the first embodiment. 同実施の形態1における一体型アクスルハウジングの平面図である。FIG. 3 is a plan view of the integrated axle housing in the first embodiment. 図3のIV-IV矢視による部分縦断面図である。FIG. 4 is a partial longitudinal sectional view taken along the line IV-IV in FIG. 3. 図4のV部拡大図である。It is the V section enlarged view of FIG. 図2のVI-VI矢視による部分横断面図である。FIG. 5 is a partial cross-sectional view taken along the line VI-VI in FIG. 2. 一体型アクスルハウジングの分解斜視図である。It is a disassembled perspective view of an integrated axle housing. 本発明の実施の形態2における一体型アクスルハウジングの正面図である。It is a front view of the integrated axle housing in Embodiment 2 of this invention. 図8のIX-IX線に沿う縦断面図である。It is a longitudinal cross-sectional view which follows the IX-IX line of FIG. 補強リングの斜視図である。It is a perspective view of a reinforcement ring. 本発明に係る一体型アクスルハウジングの製造方法の実施の形態1を示す工程図である。It is process drawing which shows Embodiment 1 of the manufacturing method of the integrated axle housing which concerns on this invention. 本発明に係る一体型アクスルハウジングの製造方法の実施の形態1における第1中間素材の形成方法の実施例1を示す工程図である。It is process drawing which shows Example 1 of the formation method of the 1st intermediate material in Embodiment 1 of the manufacturing method of the integrated axle housing which concerns on this invention. 同じく第1中間素材の形成方法の実施例2を示す工程図である。It is process drawing which similarly shows Example 2 of the formation method of the 1st intermediate material. 縮径ダイスに環状の誘導加熱コイルを設けた例を示す縦断面図である。It is a longitudinal cross-sectional view which shows the example which provided the cyclic | annular induction heating coil in the diameter reducing die. 同じく第1中間素材の形成方法の実施例3を示す工程図である。It is process drawing which similarly shows Example 3 of the formation method of a 1st intermediate material. 第2中間素材形成工程における扁平大径部の形成方法を示す工程図である。It is process drawing which shows the formation method of the flat large diameter part in a 2nd intermediate material formation process. 膨出部成形工程における突出部の形成方法を示す工程図である。It is process drawing which shows the formation method of the protrusion part in a bulging part shaping | molding process. 本発明に係る一体型アクスルハウジングの製造方法の実施の形態2を示す工程図である。It is process drawing which shows Embodiment 2 of the manufacturing method of the integral axle housing which concerns on this invention. 本発明に係る一体型アクスルハウジングの製造方法の実施の形態3を示す工程図である。It is process drawing which shows Embodiment 3 of the manufacturing method of the integrated axle housing which concerns on this invention.

以下、本発明の実施の形態における一体型アクスルハウジングについて図面を参照しながら説明する。
[一体型アクスルハウジングの実施の形態1]
Hereinafter, an integrated axle housing according to an embodiment of the present invention will be described with reference to the drawings.
[Embodiment 1 of integrated axle housing]

図1は、本発明の実施の形態1における一体型アクスルハウジングを備えた自動車の後輪懸架装置の一例を示す斜視図である。   FIG. 1 is a perspective view showing an example of a rear wheel suspension device of an automobile provided with an integrated axle housing in Embodiment 1 of the present invention.

この後輪懸架装置1は、一体型アクスルハウジング2を、例えば左右一対のリーフスプリング3で懸架したリジッドアクスル形式であり、一体型アクスルハウジング2は、車幅方向中央部に位置する膨出部5と、この膨出部5から車幅方向両側に延びるアクスルケース6とを備えている。膨出部5の前面には差動装置8が取り付けられ、アクスルケース6の両端には軸受部9が接合され、軸受部9に続いてブレーキ装置を内蔵したホイールハブ10が接合され、アクスルケース6の内部にアクスル軸11が軸支される。差動装置8の先端には連結フランジ12が設けられ、ここに図示しないプロペラシャフトが連結される。   The rear wheel suspension device 1 is a rigid axle type in which an integral axle housing 2 is suspended by, for example, a pair of left and right leaf springs 3, and the integral axle housing 2 is a bulging portion 5 located at the center in the vehicle width direction. And an axle case 6 extending from the bulging portion 5 to both sides in the vehicle width direction. A differential device 8 is attached to the front surface of the bulging portion 5, a bearing portion 9 is joined to both ends of the axle case 6, and a wheel hub 10 incorporating a brake device is joined to the bearing portion 9, followed by an axle case. Axle shaft 11 is pivotally supported inside 6. A connecting flange 12 is provided at the tip of the differential device 8, and a propeller shaft (not shown) is connected thereto.

アクスルケース6はリーフスプリング3の上に載置され、例えばU字形ボルト14と固定プレート15により固定されている。リーフスプリング3の前後端部はそれぞれピボット軸16とシャックル17により図示しない車体に連結される。また、アクスルケース6とリーフスプリング3の連結部付近と車体との間にショックアブソーバー18が連結され、ホイールハブ10には図示しない後輪が締結され、自動車の走行時における後輪及び一体型アクスルハウジング2の上下動がリーフスプリング3とショックアブソーバー18とにより緩衝、復元される。   The axle case 6 is placed on the leaf spring 3 and fixed by, for example, a U-shaped bolt 14 and a fixing plate 15. The front and rear ends of the leaf spring 3 are connected to a vehicle body (not shown) by a pivot shaft 16 and a shackle 17, respectively. A shock absorber 18 is connected between the vehicle body and the vicinity of the connecting portion between the axle case 6 and the leaf spring 3, and a rear wheel (not shown) is fastened to the wheel hub 10. The vertical movement of the housing 2 is buffered and restored by the leaf spring 3 and the shock absorber 18.

図2は一体型アクスルハウジング2の正面図、図3は同じく平面図である。また、図4は図3のIV-IV矢視による部分縦断面図、図5は図4のV部拡大図、図6は図2のVI-VI矢視による部分横断面図、図7は一体型アクスルハウジング2の分解斜視図である。   2 is a front view of the integrated axle housing 2, and FIG. 3 is a plan view of the same. 4 is a partial longitudinal sectional view taken along the line IV-IV in FIG. 3, FIG. 5 is an enlarged view of a part V in FIG. 4, FIG. 6 is a partial transverse sectional view taken along the line VI-VI in FIG. 2 is an exploded perspective view of an integrated axle housing 2. FIG.

この一体型アクスルハウジング2の膨出部5とアクスルケース6は、その製造方法を後に詳述するように、閉断面を有する1本のパイプ素材を塑性加工することにより一体に形成されている。アクスルケース6は円筒形状であり、その径方向の断面積が、膨出部5の径方向の断面積の数分の一である。膨出部5には差動装置8の後半部が収容され、アクスルケース6の内部に軸支されたアクスル軸11が駆動される。   The bulging portion 5 and the axle case 6 of the integrated axle housing 2 are integrally formed by plastic processing a single pipe material having a closed cross section, as will be described in detail later. The axle case 6 has a cylindrical shape, and its radial cross-sectional area is a fraction of the radial cross-sectional area of the bulging portion 5. The bulging portion 5 accommodates the latter half portion of the differential device 8, and the axle shaft 11 that is pivotally supported inside the axle case 6 is driven.

図4〜図7に示すように、膨出部5は平坦な補強リング取付面21と、この補強リング取付面21に対向する膨出面22とを有し、特に図7に示すように、補強リング取付面21には円形の開口部23が穿設され、その周囲に例えば8つの前部挿通穴24が等間隔に設けられている。また、膨出面22の中央付近には後方に突出する突出部25が形成され、この突出部25の周囲には、補強リング取付面21の8つの前部挿通穴24の位置に整合する8つの後部挿通穴26(図5参照)が形成されている。   As shown in FIGS. 4 to 7, the bulging portion 5 has a flat reinforcing ring mounting surface 21 and a bulging surface 22 opposite to the reinforcing ring mounting surface 21, and particularly as shown in FIG. A circular opening 23 is formed in the ring mounting surface 21 and, for example, eight front insertion holes 24 are provided at equal intervals around the opening 23. Further, a projecting portion 25 projecting rearward is formed in the vicinity of the center of the bulging surface 22, and around the projecting portion 25, eight positions that are aligned with the positions of the eight front insertion holes 24 of the reinforcing ring mounting surface 21 are formed. A rear insertion hole 26 (see FIG. 5) is formed.

一方、差動装置8はデフキャリア28を備え、このデフキャリア28の後端に設けられた接合フランジ29の部分が後述する補強リング36を介して補強リング取付面21に接合される。デフキャリア28の内部にはピニオンシャフト30が前後方向に軸支され、このピニオンシャフト30の後部にピニオンギヤ31が設けられている。   On the other hand, the differential 8 includes a differential carrier 28, and a portion of a joint flange 29 provided at the rear end of the differential carrier 28 is joined to a reinforcing ring mounting surface 21 via a reinforcing ring 36 described later. Inside the differential carrier 28, a pinion shaft 30 is pivotally supported in the front-rear direction, and a pinion gear 31 is provided at the rear portion of the pinion shaft 30.

デフキャリア28の後部にはピニオンギヤ31に噛合するリングギヤ32とデフギヤケース33(図6参照)とが軸支され、これらの部材32,33が開口部23を経て膨出部5の内部に挿入される。その際、リングギヤ32とデフギヤケース33の回転中心軸線がアクスルケース6の軸心に合致し、左右のアクスル軸11の内端がデフギヤケース33に内装された図示しないデフギヤに連結される。デフギヤケース33及びデフギヤは周知の構造である。   A ring gear 32 and a differential gear case 33 (see FIG. 6) meshing with the pinion gear 31 are pivotally supported at the rear portion of the differential carrier 28, and these members 32 and 33 are inserted into the bulging portion 5 through the opening 23. The At this time, the rotation center axes of the ring gear 32 and the differential gear case 33 coincide with the axis of the axle case 6, and the inner ends of the left and right axle shafts 11 are connected to a differential gear (not shown) housed in the differential gear case 33. The differential gear case 33 and the differential gear have a known structure.

補強リング36は、環状且つ平板状のリング本体37と、8本のパイプ状の連結補強部材38とを備えて形成されており、リング本体37には8つのボルト穴39が等間隔に穿設され、これら各ボルト穴39の位置に整合して補強リング36の後面側に連結補強部材38の一端が固着され、連結補強部材38は車体前後方向に沿うように延びる。図5に示すように、連結補強部材38とリング本体37との接合部40は、例えば全周溶接により接合される。なお、従来からリング本体のみからなる補強リングは存在しており、これを開口部23の周囲の面に接合することにより、開口部23周囲の面の肉厚を増大させて膨出部5の強度低下が補強されていた。   The reinforcing ring 36 includes an annular and flat ring main body 37 and eight pipe-shaped connecting reinforcing members 38. The ring main body 37 has eight bolt holes 39 formed at equal intervals. Then, one end of the connection reinforcing member 38 is fixed to the rear surface side of the reinforcing ring 36 in alignment with the position of each bolt hole 39, and the connection reinforcing member 38 extends along the longitudinal direction of the vehicle body. As shown in FIG. 5, the joint 40 between the connection reinforcing member 38 and the ring main body 37 is joined by, for example, all-around welding. Conventionally, there is a reinforcing ring consisting only of the ring body, and by joining this to the surface around the opening 23, the thickness of the surface around the opening 23 is increased to increase the thickness of the bulging portion 5. Strength reduction was reinforced.

本実施形態においても、図5に示すように補強リング36のリング本体37が補強リング取付面21の開口部23周囲に密着されて接合部41において全周溶接され、これにより開口部23の周囲の面が補強される。同時に、リング本体37から後方に延びる8本の連結補強部材38が、それぞれ補強リング取付面21の前部挿通穴24と膨出面22の後部挿通穴26とを貫通し、各連結補強部材38の後端が膨出面22から短く後方に突出し、この突出部と膨出面22との間が接合部42において全周溶接される。   Also in the present embodiment, as shown in FIG. 5, the ring body 37 of the reinforcing ring 36 is in close contact with the periphery of the opening 23 of the reinforcing ring mounting surface 21 and is welded all around the joint 41, thereby The surface of is reinforced. At the same time, eight connection reinforcing members 38 extending rearward from the ring body 37 penetrate the front insertion holes 24 of the reinforcing ring mounting surface 21 and the rear insertion holes 26 of the bulging surface 22, respectively. The rear end protrudes rearward shortly from the bulging surface 22, and the entire circumference is welded between the protruding portion and the bulging surface 22 at the joint portion.

差動装置8を膨出部5に締結する8本の通しボルト44は、車体前方から、差動装置8の接合フランジ29と、リング本体37と、パイプ状の連結補強部材38とを通って連結補強部材38の後端から外部に突出し、ここにワッシャー45を介してナット46が締結される。従って、通しボルト44とナット46とにより差動装置8と補強リング36と膨出部5とが共締めされる。   Eight through bolts 44 for fastening the differential device 8 to the bulging portion 5 are passed from the front of the vehicle body through the joining flange 29, the ring body 37, and the pipe-shaped connecting reinforcing member 38 of the differential device 8. It protrudes outside from the rear end of the connection reinforcing member 38, and a nut 46 is fastened thereto via a washer 45. Accordingly, the differential gear 8, the reinforcing ring 36 and the bulging portion 5 are fastened together by the through bolt 44 and the nut 46.

以上のように、一体型アクスルハウジング2の膨出部5とアクスルケース6とを、閉断面を有する1本のパイプ素材を塑性加工して形成することにより、従来のように金属板をプレス加工して形成した多数の部分品を溶接により接合してアクスルハウジングを形成することに比べて、構成部品点数及び溶接部位を大幅に削減して一体型アクスルハウジング2の製造を容易にし、その品質を低下させることなく製造コストダウンと軽量化を図ることができる。   As described above, the bulging portion 5 of the integrated axle housing 2 and the axle case 6 are formed by plastic working a single pipe material having a closed cross section, thereby pressing a metal plate as in the past. Compared to forming an axle housing by welding a large number of parts formed by welding, the number of components and the welding site are greatly reduced, making the integrated axle housing 2 easier to manufacture and improving its quality. The manufacturing cost can be reduced and the weight can be reduced without lowering.

また、膨出部5に、開口部23を有する補強リング取付面21と、この補強リング取付面21に対向する膨出面22とを形成し、開口部23の周囲に補強リング36を接合して開口部23を補強しながら差動装置8を固定すると共に、補強リング36に設けた連結補強部材38によって補強リング取付面21と膨出面22との間を堅固に連結したため、差動装置8が収容される膨出部5の全体的な強度を飛躍的に高めることができる。   Further, a reinforcing ring mounting surface 21 having an opening 23 and a bulging surface 22 opposite to the reinforcing ring mounting surface 21 are formed on the bulging portion 5, and a reinforcing ring 36 is joined around the opening 23. The differential device 8 is fixed while reinforcing the opening 23, and the reinforcing ring mounting surface 21 and the bulging surface 22 are firmly connected by the connecting reinforcing member 38 provided on the reinforcing ring 36. It is possible to dramatically increase the overall strength of the bulging portion 5 to be accommodated.

さらに、補強リング36に設けた連結補強部材38をパイプ状且つ車体前後方向に沿うように形成し、この連結補強部材38に、差動装置8を膨出部5に締結する通しボルト44を挿通し、この通しボルト44とナット46とにより、差動装置8と補強リング36と膨出部5とを共締めしたため、膨出部5の強度を著しく高めると同時に、通しボルト44と連結補強部材38とを同軸状に配置してスペースを削減し、ひいては一体型アクスルハウジング2の小型軽量化に多大に貢献することができる。
[一体型アクスルハウジングの実施の形態2]
Further, a connecting reinforcing member 38 provided on the reinforcing ring 36 is formed in a pipe shape along the longitudinal direction of the vehicle body, and a through bolt 44 for fastening the differential device 8 to the bulging portion 5 is inserted into the connecting reinforcing member 38. Since the differential gear 8, the reinforcing ring 36, and the bulging portion 5 are fastened together by the through bolt 44 and the nut 46, the strength of the bulging portion 5 is remarkably increased, and at the same time, the through bolt 44 and the connecting reinforcing member 38 can be arranged coaxially to reduce the space, and thus contribute greatly to the reduction in size and weight of the integrated axle housing 2.
[Embodiment 2 of integrated axle housing]

図8は、本発明の実施の形態2における一体型アクスルハウジングの正面図であり、図9は図8のIX-IX線に沿う縦断面図であり、図10は補強リングの斜視図である。   8 is a front view of an integrated axle housing according to Embodiment 2 of the present invention, FIG. 9 is a longitudinal sectional view taken along line IX-IX in FIG. 8, and FIG. 10 is a perspective view of a reinforcing ring. .

この一体型アクスルハウジング2aは、その補強リング36aの形態と、差動装置8との結合状態が実施の形態1の一体型アクスルハウジング2と異なっており、他の部分は同一の構成であるため、異なる部分についてのみ説明し、同一構成の部分には同一符号を付して説明を省略する。   This integrated axle housing 2a is different from the integrated axle housing 2 of the first embodiment in the form of the reinforcing ring 36a and the coupling state with the differential gear 8, and the other parts have the same configuration. Only the different parts will be described, and the same reference numerals are given to the parts having the same configuration, and the description will be omitted.

図10に示すように、補強リング36aは、環状且つ平板状のリング本体37aと、4本のパイプ状の連結補強部材38aとを備えており、リング本体37aには、例えば4つのボルト穴39aと、4つの雌ネジ39bとが、交互且つ等間隔に形成されている。4本の連結補強部材38aは、4つのボルト穴39aの位置に整合して補強リング36の後面側に固着され、車体前後方向に沿うように延びる。このため、連結補強部材38aが設けられている部分の間に雌ネジ39bが配置されている。   As shown in FIG. 10, the reinforcing ring 36a includes an annular and flat ring main body 37a and four pipe-shaped connecting reinforcing members 38a. The ring main body 37a has, for example, four bolt holes 39a. And four female screws 39b are formed alternately and at equal intervals. The four connecting reinforcing members 38a are fixed to the rear surface side of the reinforcing ring 36 in alignment with the positions of the four bolt holes 39a, and extend along the longitudinal direction of the vehicle body. For this reason, the female screw 39b is disposed between the portions where the connection reinforcing member 38a is provided.

補強リング36aのリング本体37aは、補強リング取付面21の開口部23周囲に接合され、連結補強部材38aが補強リング取付面21と膨出面22を貫通し、その後端が膨出面22から短く後方に突出し、この突出部と膨出面22との間が全周溶接等により固着される。   The ring body 37a of the reinforcing ring 36a is joined to the periphery of the opening 23 of the reinforcing ring mounting surface 21, the connecting reinforcing member 38a passes through the reinforcing ring mounting surface 21 and the bulging surface 22, and the rear end is short from the bulging surface 22 to the rear. The projecting portion and the bulging surface 22 are fixed to each other by welding all around.

そして、4本の連結補強部材38aには、図8に示すように、差動装置8の接合フランジ29を一体型アクスルハウジング2aに固定するための通しボルト44aが挿通され、反対側からナットが締結されて通しボルト44aとナットとにより差動装置8と補強リング36aと膨出部5とが共締めされる。この締結構造は図5に示したものと同様である。   Then, as shown in FIG. 8, through bolts 44a for fixing the joint flange 29 of the differential gear 8 to the integrated axle housing 2a are inserted into the four connecting reinforcing members 38a, and nuts are inserted from the opposite side. The differential 8, the reinforcing ring 36a, and the bulging portion 5 are fastened together by the fastening bolts 44a and the nuts. This fastening structure is the same as that shown in FIG.

また、図8及び図9に示すように、リング本体37aの雌ネジ39bには、差動装置8の接合フランジ29がボルト44bで締結される。リング本体37aは厚みが15〜20mm程度と大きいため、雌ネジ39bのネジ山を多数形成することができ、ボルト44bに充分な締結力を付与することができる。   As shown in FIGS. 8 and 9, the joint flange 29 of the differential device 8 is fastened to the female screw 39b of the ring body 37a with a bolt 44b. Since the ring body 37a has a large thickness of about 15 to 20 mm, a large number of threads of the female screw 39b can be formed, and a sufficient fastening force can be applied to the bolt 44b.

こうして、差動装置8は、補強リング36aを介し、4本の通しボルト44aと、4本のボルト44bとにより、一体型アクスルハウジング2aの膨出部5に堅固に固定される。   Thus, the differential 8 is firmly fixed to the bulging portion 5 of the integrated axle housing 2a by the four through bolts 44a and the four bolts 44b through the reinforcing ring 36a.

このように、差動装置8を膨出部5に固定する複数のボルト44a,44bのうちの半数のボルト(通しボルト44a)を補強リング36aと共締めし、残る半数のボルト(ボルト44b)をリング本体37aに形成した雌ネジ39bに締結することにより、補強リング36aの連結補強部材38aによって膨出部5の強度を向上させると同時に、膨出部5の内部における差動装置8の関連部品(ピニオンギヤ31、リングギヤ32、デフギヤケース33等)の配置自由度を向上させ、これらの効果により一体型アクスルハウジング2aの小型軽量化を図ることができ、しかも差動装置8を膨出部5に堅固に固定することができる。   In this way, half of the plurality of bolts 44a, 44b (through bolt 44a) for fixing the differential device 8 to the bulging portion 5 are fastened together with the reinforcing ring 36a, and the remaining half of the bolt (bolt 44b). Is fastened to a female screw 39b formed on the ring body 37a, so that the strength of the bulging portion 5 is improved by the connection reinforcing member 38a of the reinforcing ring 36a. The degree of freedom of arrangement of parts (pinion gear 31, ring gear 32, differential gear case 33, etc.) can be improved, and the integrated axle housing 2a can be reduced in size and weight due to these effects. It can be firmly fixed to.

なお、上記一体型アクスルハウジングの実施の形態1及び2では、自動車の後輪懸架装置に本発明が適用された例について説明したが、例えば4輪駆動車のように、前輪にも差動装置が設けられる場合においては、前輪懸架装置にも本発明に係る一体型アクスルハウジングを適用することができる。   In the first and second embodiments of the integrated axle housing, an example in which the present invention is applied to a rear wheel suspension device of an automobile has been described. However, for example, as in a four-wheel drive vehicle, a differential device is also applied to a front wheel. Is provided, the integrated axle housing according to the present invention can also be applied to the front wheel suspension device.

次に、一体型アクスルハウジング2(2a)の製造方法について説明する。
[一体型アクスルハウジングの製造方法の実施の形態1]
Next, a method for manufacturing the integrated axle housing 2 (2a) will be described.
[Embodiment 1 of Manufacturing Method of Integrated Axle Housing]

図11(a)〜(f)は、本発明の実施の形態1に係る一体型アクスルハウジング2(2a)の製造方法を示す工程図である。この製造方法は、第1中間素材形成工程Aと、第2中間素材形成工程Bと、開口部形成工程Cと、膨出部成形工程Dと、穴開け工程Eとを有している。   11 (a) to 11 (f) are process diagrams showing a method for manufacturing the integrated axle housing 2 (2a) according to the first embodiment of the present invention. This manufacturing method includes a first intermediate material forming process A, a second intermediate material forming process B, an opening forming process C, a bulging part forming process D, and a punching process E.

一体型アクスルハウジング2(2a)の材料となるのは、図11(a)に示すように、所定の長さ、外径、肉厚を有するパイプ素材50である。第1中間素材形成工程Aでは、後に詳述するように、このパイプ素材50の両端をスウェージング加工等の塑性加工により縮径するか、或いは逆にパイプ素材50の中間部を拡径し、図11(b)に示すように中間部に位置する中央大径部51と、この中央大径部51の両側に位置し、中央大径部51の外径よりも小径な一対の小径部52とを有する第1中間素材53を形成する。   The material of the integrated axle housing 2 (2a) is a pipe material 50 having a predetermined length, outer diameter, and thickness as shown in FIG. 11 (a). In the first intermediate material forming step A, as described in detail later, both ends of the pipe material 50 are reduced in diameter by plastic processing such as swaging, or conversely, the intermediate portion of the pipe material 50 is expanded in diameter, As shown in FIG. 11 (b), a central large-diameter portion 51 located in the middle portion, and a pair of small-diameter portions 52 located on both sides of the central large-diameter portion 51 and having a smaller diameter than the outer diameter of the central large-diameter portion 51. The first intermediate material 53 having the following is formed.

第2中間素材形成工程Bでは、図11(b)に示す第1中間素材53の中央大径部51を径方向に押圧することにより、図11(c)に示すように扁平化させて扁平大径部55とした第2中間素材56を形成する。扁平大径部55の厚みは、小径部52の外径以上に設定される。   In the second intermediate material forming step B, the central large-diameter portion 51 of the first intermediate material 53 shown in FIG. 11 (b) is pressed in the radial direction to flatten and flatten as shown in FIG. 11 (c). A second intermediate material 56 having a large diameter portion 55 is formed. The thickness of the flat large diameter portion 55 is set to be equal to or larger than the outer diameter of the small diameter portion 52.

開口部形成工程Cでは、図11(c)に示す第2中間素材56の扁平大径部55の前面に、図11(d)に示すように差動装置8挿入用の開口部23を形成する。   In the opening forming step C, the opening 23 for inserting the differential device 8 is formed on the front surface of the flat large diameter portion 55 of the second intermediate material 56 shown in FIG. 11 (c) as shown in FIG. 11 (d). To do.

膨出部成形工程Dでは、図11(e)に示すように、扁平大径部55の、開口部23に対向する後面を、開口部23から離反する方向に突出成形することにより突出部25を形成する。   In the bulging portion forming step D, as shown in FIG. 11 (e), the rear surface of the flat large diameter portion 55 that faces the opening 23 is formed by protruding in a direction away from the opening 23, thereby forming the protrusion 25. Form.

穴開け工程Eでは、図11(f)に示すように、開口部23の周囲に補強リング36の連結補強部材38挿入用の挿通穴24を形成すると共に、突出部25の周囲に後部挿通穴26を形成し、これによって扁平大径部55が差動装置8の後部を収容可能な膨出部5としての最終形状に造形され、小径部52はそのままアクスルケース6となり、一体型アクスルハウジング2(2a)が完成する。   In the drilling step E, as shown in FIG. 11 (f), an insertion hole 24 for inserting the connection reinforcing member 38 of the reinforcing ring 36 is formed around the opening 23, and a rear insertion hole is formed around the protrusion 25. Thus, the flat large-diameter portion 55 is formed into a final shape as the bulging portion 5 capable of accommodating the rear portion of the differential device 8, and the small-diameter portion 52 becomes the axle case 6 as it is, so that the integrated axle housing 2 is formed. (2a) is completed.

以下、上述した第1中間素材形成工程Aにおける第1中間素材53の形成方法として好適な3つの実施例を、図12〜図15に基いて順に説明する。
[実施例1]
Hereinafter, three examples suitable as a method for forming the first intermediate material 53 in the first intermediate material forming step A will be described in order based on FIGS. 12 to 15.
[Example 1]

図12(a)〜(d)は、第1中間素材53の形成方法の実施例1を示す工程図である。まず、図12(a)に示すように、所定の長さ、外径、肉厚を有するパイプ素材50を用意する。この塑性加工する前のパイプ素材50の外径は、完成した第1中間素材53の中央大径部51の外径と略一致したものとする。   12A to 12D are process diagrams showing Example 1 of the method for forming the first intermediate material 53. First, as shown in FIG. 12 (a), a pipe material 50 having a predetermined length, outer diameter, and thickness is prepared. It is assumed that the outer diameter of the pipe material 50 before the plastic working substantially coincides with the outer diameter of the central large diameter portion 51 of the completed first intermediate material 53.

次に、図12(b)及び図12(c)に示すように、例えば数種類の縮径ダイス59,60…を用いてパイプ素材50をその両端から中央部に向かって縮径加工し、パイプ素材50の中央部は縮径させないでおくことにより、図12(d)に示すように中央大径部51と一対の小径部52とを有する第1中間素材53として完成させる。   Next, as shown in FIG. 12 (b) and FIG. 12 (c), for example, the pipe material 50 is reduced in diameter from its both ends toward the center using several kinds of reduced diameter dies 59, 60. By not reducing the diameter of the central portion of the material 50, a first intermediate material 53 having a central large diameter portion 51 and a pair of small diameter portions 52 is completed as shown in FIG. 12 (d).

ここで、縮径ダイス59,60のテーパー部61,62の角度は、縮径が進むにつれて、即ち縮径ダイス59,60の内径が小さくなるにつれて急角度なものに変更していくのが好ましい。これにより、縮径加工時においてパイプ素材50の断面形状が急激に変形することを避け、パイプ素材50の破断や皺の発生といった加工欠陥を排除し、スムーズ且つ綺麗に縮径させると共に、縮径加工の合理化、又は縮径金型の小型化を図ることができる。   Here, the angles of the tapered portions 61 and 62 of the reduced diameter dies 59 and 60 are preferably changed to a steep angle as the diameter decreases, that is, as the inner diameter of the reduced diameter dies 59 and 60 decreases. . This avoids sudden deformation of the cross-sectional shape of the pipe material 50 during diameter reduction processing, eliminates processing defects such as breakage of the pipe material 50 and generation of wrinkles, and reduces the diameter smoothly and beautifully. Rationalization of processing or downsizing of the reduced diameter mold can be achieved.

パイプ素材50の縮径が進むにつれて縮径部の全長は伸びてゆき、これにより縮径部の肉厚がパイプ素材50の元の肉厚よりも薄くなるか、或いはほぼ同じ肉厚に保たれる。このように、縮径によりパイプ素材50の肉厚が変化することを勘案して予めパイプ素材50の元の肉厚を設定しておく。なお、縮径と同時にパイプ素材50の端部を牽引して延ばし、小径部52の長さを設定してもよい。   As the diameter of the pipe material 50 progresses, the overall length of the diameter-reduced portion grows, so that the thickness of the diameter-reduced portion becomes thinner than the original thickness of the pipe material 50 or is kept approximately the same. It is. As described above, the original thickness of the pipe material 50 is set in advance in consideration of the change in the thickness of the pipe material 50 due to the diameter reduction. The length of the small diameter portion 52 may be set by pulling and extending the end portion of the pipe material 50 simultaneously with the diameter reduction.

この形成方法によれば、パイプ素材50の、中央大径部51が形成される部分が引き延ばされることがないため、最も強度が必要な中央大径部51の肉厚を厚く確保し、最終的に完成した一体型アクスルハウジング2(2a)の膨出部5の肉厚がアクスルケース6の肉厚よりも薄肉になって強度が不足するといった事態を回避することができる。
[実施例2]
According to this forming method, since the portion of the pipe material 50 where the central large diameter portion 51 is formed is not stretched, the thickness of the central large diameter portion 51 that requires the most strength is ensured to be thick, and the final Thus, it is possible to avoid such a situation that the thickness of the bulging portion 5 of the completed integrated axle housing 2 (2a) becomes thinner than the thickness of the axle case 6 and the strength is insufficient.
[Example 2]

図13(a)〜(f)は、第1中間素材53の形成方法の実施例2を示す工程図である。まず、図13(a)に示すように、所定の長さ、外径、肉厚を有するパイプ素材50を用意する。この塑性加工する前のパイプ素材50の外径は、完成した第1中間素材53の小径部52の外径と略同じものとする。   FIGS. 13A to 13F are process diagrams showing Example 2 of the method for forming the first intermediate material 53. First, as shown in FIG. 13 (a), a pipe material 50 having a predetermined length, outer diameter, and thickness is prepared. The outer diameter of the pipe material 50 before the plastic working is substantially the same as the outer diameter of the small diameter portion 52 of the completed first intermediate material 53.

次に、図13(b)に示すように、パイプ素材50を、その一端L側から所定の長さ、例えばパイプ素材50の中間点Mを越えた位置まで拡径する。この拡径工程は、例えば2段階の内径65,66及びテーパー状の段差部67を持つシリンダー型の拡径冶具68にパイプ素材50を挿入しながら行う。拡径冶具68の細い方の内径65はパイプ素材50を密に挿入できる大きさであり、太い方の内径66は拡開が完了したパイプ素材50の外径と同じに設定されている。   Next, as shown in FIG. 13 (b), the diameter of the pipe material 50 is expanded from its one end L side to a predetermined length, for example, a position beyond the intermediate point M of the pipe material 50. This diameter expansion process is performed while inserting the pipe material 50 into a cylinder-type diameter expansion jig 68 having, for example, two stages of inner diameters 65 and 66 and a tapered stepped portion 67. The narrow inner diameter 65 of the diameter expansion jig 68 is large enough to insert the pipe material 50 closely, and the thick inner diameter 66 is set to be the same as the outer diameter of the pipe material 50 that has been expanded.

そして、拡径冶具68に挿入されたパイプ素材50の一端L側に拡径ダイス69を圧入し、拡径ダイス69が拡径冶具68の段差部67に当接するまで押し込んでパイプ素材50の内径を拡径する。これにより、図13(c)に示すように、パイプ素材50はその一端L側から所定の長さまでが拡径された段付きパイプ状に成形される。なお、この拡径工程では、径及びテーパー度の異なる拡径ダイス69を複数用意し、段階的にパイプ素材50を拡径させてもよい。   Then, a diameter expanding die 69 is press-fitted into one end L side of the pipe material 50 inserted in the diameter expanding jig 68, and the diameter expanding die 69 is pushed in until it abuts on the stepped portion 67 of the diameter expanding jig 68, so that the inner diameter of the pipe material 50 is increased. Increase the diameter. Thus, as shown in FIG. 13 (c), the pipe material 50 is formed into a stepped pipe shape whose diameter is expanded from the one end L side to a predetermined length. In this diameter expansion step, a plurality of diameter expansion dies 69 having different diameters and taper degrees may be prepared, and the pipe material 50 may be expanded in stages.

次に、図13(d)及び図13(e)に示すように、パイプ素材50を拡径冶具68に保持させたまま、或いは別な保持部材に保持させた状態で、パイプ素材50の拡径された部分を、その一端Lから中間点Mよりも手前の位置M´まで縮径する。この縮径工程は、例えば実施例1の場合と同様に、異なる内径及びテーパー角度を持つ複数の縮径ダイス71,72…を用いた縮径加工により行う。これにより、図13(f)に示すように、中央大径部51と一対の小径部52とを有する第1中間素材53が完成する。   Next, as shown in FIGS. 13 (d) and 13 (e), the pipe material 50 is expanded while the pipe material 50 is held by the diameter expansion jig 68 or held by another holding member. The diameter-reduced portion is reduced in diameter from one end L thereof to a position M ′ before the intermediate point M. This diameter reduction process is performed by diameter reduction processing using a plurality of diameter reduction dies 71, 72,... Having different inner diameters and taper angles, for example, as in the case of the first embodiment. As a result, as shown in FIG. 13 (f), the first intermediate material 53 having the central large diameter portion 51 and the pair of small diameter portions 52 is completed.

なお、実施例1及び実施例2において、縮径加工時に用いる縮径ダイス59,60,71,72に、図14に示すようなパイプ素材50を囲む環状の誘導加熱コイル74を設け、パイプ素材50を縮径する直前に加熱することにより、よりスムーズ且つ省力的に縮径させることができる。この誘導加熱コイル74を設ける場所は、必ずしも図14に示す場所でなくても良いが、パイプ素材50を縮径する際にパイプ素材50が干渉せず、且つパイプ素材50に近接した場所に設置することが望ましい。
[実施例3]
In Example 1 and Example 2, an annular induction heating coil 74 surrounding the pipe material 50 as shown in FIG. 14 is provided on the diameter-reducing dies 59, 60, 71, 72 used in diameter-reducing processing, and the pipe material is provided. By heating 50 immediately before reducing the diameter, the diameter can be reduced more smoothly and labor-saving. The place where the induction heating coil 74 is provided is not necessarily the place shown in FIG. 14, but the pipe material 50 does not interfere when the diameter of the pipe material 50 is reduced, and the induction heating coil 74 is installed in a place close to the pipe material 50. It is desirable to do.
[Example 3]

図15(a)〜(d)は、第1中間素材53の形成方法の実施例3を示す工程図である。まず、図15(a)に示すパイプ素材50を用意する。このパイプ素材50の外径は、完成した第1中間素材53の小径部52の外径と略同じものとする。また、パイプ素材50の全長L1は、完成した第1中間素材53の全長L2(図15(d)参照)よりも若干長いものとする。   FIGS. 15A to 15D are process diagrams showing Example 3 of the method for forming the first intermediate material 53. First, a pipe material 50 shown in FIG. 15 (a) is prepared. The outer diameter of the pipe material 50 is substantially the same as the outer diameter of the small diameter portion 52 of the completed first intermediate material 53. The total length L1 of the pipe material 50 is slightly longer than the total length L2 of the completed first intermediate material 53 (see FIG. 15 (d)).

次に、図15(b)に示すように、パイプ素材50を分割金型77の内部に設置する。この分割金型77は、例えば上型78と下型79とを備えた上下2つ割りの金型であり、その成形室80の形状が、完成した第1中間素材53の形状と同じ形状に造形されている。   Next, as shown in FIG. 15 (b), the pipe material 50 is installed inside the split mold 77. The split mold 77 is, for example, an upper and lower split mold including an upper mold 78 and a lower mold 79. The shape of the molding chamber 80 is the same as the shape of the completed first intermediate material 53. It is shaped.

成形室80は、第1中間素材53の小径部52の外径と同じ内径の円柱室82と、この円柱室82の中間に位置する膨張室81からなり、円柱室82の両側の外端部は外部に開放され、ここに一対の押圧ピストン83が密に、且つ円柱室82の長手方向に沿って摺動自在に挿入されている。 Molding chamber 80 includes a cylindrical chamber 82 having the same inner diameter as the outer diameter of the small diameter portion 52 of the first intermediate material 53, made from the expansion chamber 81 located in the middle of the cylinder chamber 82, the outer end portions on both sides of the cylindrical chamber 82 Is opened to the outside, and a pair of pressing pistons 83 are inserted in a dense manner and slidable along the longitudinal direction of the cylindrical chamber 82 .

そして、図15(c)に示すように、パイプ素材50の内部に流体圧力を加えると同時に、両側の押圧ピストン83でパイプ素材50の端面を軸方向に押圧し、膨張室81の内部でパイプ素材50の中間部を膨張させながらパイプ素材50を初期の長さL1から完成品の長さL2に短縮させる。これによって図15(d)に示すように中央大径部51と一対の小径部52とを備えた第1中間素材53を完成させる。上記流体圧力としては、液圧や低温溶融金属の圧力等、多種のものが考えられる。 Then, as shown in FIG. 15 (c), fluid pressure is applied to the inside of the pipe material 50, and at the same time, the end surfaces of the pipe material 50 are pressed in the axial direction by the pressing pistons 83 on both sides, and the pipe inside the expansion chamber 81 While expanding the intermediate portion of the material 50, the pipe material 50 is shortened from the initial length L1 to the length L2 of the finished product. Thereby, as shown in FIG. 15D, a first intermediate material 53 having a central large diameter portion 51 and a pair of small diameter portions 52 is completed. As the fluid pressure, various pressures such as liquid pressure and low-temperature molten metal pressure are conceivable.

このように、パイプ素材50の内部に流体圧力を加えて膨張室81の内部でパイプ素材50の中間部を膨張させると同時に、押圧ピストン83でパイプ素材50の端面を軸方向に押圧してパイプ素材50を初期の長さL1から完成品の長さL2に短縮させれば、パイプ素材50の中間部が膨張する際に肉厚が薄くなることが防止され、強度が低下することを効果的に防止することができる。 In this way, fluid pressure is applied to the inside of the pipe material 50 to expand the intermediate portion of the pipe material 50 inside the expansion chamber 81 , and at the same time, the end surface of the pipe material 50 is pressed in the axial direction by the pressing piston 83. If the material 50 is shortened from the initial length L1 to the length L2 of the finished product, it is possible to prevent the thickness from being reduced when the intermediate portion of the pipe material 50 expands, and to reduce the strength effectively. Can be prevented.

なお、パイプ素材50の中間部を予め加熱してから分割金型77の内部に設置して上記加圧成形を行うようにすれば、パイプ素材50の膨張変形を容易にでき、歩留まりを向上させると共に、流体圧力を小さくして省力化を図り、しかも分割金型77の寿命を大幅に延ばすことができる。   In addition, if the intermediate part of the pipe material 50 is preheated and then placed in the split mold 77 to perform the above-described pressure molding, the pipe material 50 can be easily expanded and deformed, and the yield can be improved. At the same time, the fluid pressure can be reduced to save labor, and the life of the split mold 77 can be greatly extended.

次に、図11と共に先述した第2中間素材形成工程Bにおける扁平大径部55の形成方法と、膨出部成形工程Dにおける突出部25の形成方法について説明する。   Next, a method for forming the flat large diameter portion 55 in the second intermediate material forming step B described above with reference to FIG. 11 and a method for forming the protruding portion 25 in the bulging portion forming step D will be described.

第2中間素材形成工程Bでは、図16(a)に示すように、第1中間素材53の中央大径部51を、例えばプレス装置のベッド84とクロスヘッド85との間に設置し、次に図16(b)に示すように、クロスヘッド85にラム圧を加えて中央大径部51をプレス成形することにより、中央大径部51を径方向に押圧し、扁平化させて扁平大径部55に変形させ、第1中間素材53を第2中間素材56として完成させる。   In the second intermediate material forming step B, as shown in FIG. 16 (a), the central large-diameter portion 51 of the first intermediate material 53 is installed, for example, between the bed 84 and the cross head 85 of the press device. 16 (b), by applying ram pressure to the cross head 85 and press-molding the central large-diameter portion 51, the central large-diameter portion 51 is pressed in the radial direction, flattened, and flattened. The first intermediate material 53 is completed as the second intermediate material 56 by deforming into a diameter portion 55.

膨出部成形工程Dでは、上述のように形成した扁平大径部55を、図17(a)に示すように、所定の凹み形状86を有する凹金型87の上に、その後面が下になるように載置し、先述の開口部形成工程Cにおいて既に扁平大径部55の前面に穿設されている差動装置8を挿入するための開口部23から、図17(b)に示すように所定の凸形状を有する凸金型88を突き込むことにより、扁平大径部55の後面を凹金型87の凹み形状86内にプレス成形して突出部25を形成し、図17(c)に示すように一体型アクスルハウジング2(2a)を完成させる。   In the bulging portion forming step D, the flat large diameter portion 55 formed as described above is placed on a concave mold 87 having a predetermined concave shape 86 and its rear surface is lowered as shown in FIG. 17 (a). From the opening 23 for inserting the differential device 8 already drilled in the front surface of the flat large diameter portion 55 in the opening forming step C described above, FIG. As shown in FIG. 17, by projecting a convex mold 88 having a predetermined convex shape, the rear surface of the flat large diameter portion 55 is press-molded into the concave shape 86 of the concave mold 87 to form the protruding portion 25. As shown in (c), the integrated axle housing 2 (2a) is completed.

以上のように、実施の形態1に係る一体型アクスルハウジングの製造方法によれば、1本のパイプ素材50から一体型アクスルハウジング2(2a)を容易に製造することができ、従来のように多数のプレス成形部品を溶接して接合する製造方法に比べて溶接箇所を大幅に減少させ、これにより一体型アクスルハウジング2(2a)の製造コストを安くすると共に、溶接部に欠陥が発生する懸念を払拭して高い信頼性を確保することができる。しかも、複数のプレス成形部品を製造する必要が無いため、加工工数を低減すると同時に材料の無駄を省き、この点でも製造コストを抑えることができる。
[一体型アクスルハウジングの製造方法の実施の形態2]
As described above, according to the method for manufacturing an integrated axle housing according to the first embodiment, the integrated axle housing 2 (2a) can be easily manufactured from one pipe material 50, as in the conventional case. Compared to a manufacturing method in which a large number of press-formed parts are welded together, the number of welding points is greatly reduced, thereby reducing the manufacturing cost of the integrated axle housing 2 (2a) and causing a defect in the welded portion. The high reliability can be ensured by wiping away. In addition, since it is not necessary to manufacture a plurality of press-molded parts, it is possible to reduce processing man-hours and at the same time to save material, and to reduce manufacturing costs in this respect.
[Embodiment 2 of Manufacturing Method of Integrated Axle Housing]

図18(a)〜(d)は、本発明の実施の形態2に係る一体型アクスルハウジングの製造方法を示す工程図である。この製造方法は、外径が一定のパイプ素材を分割金型の内部に設置し、このパイプ素材の内部に流体圧力を加えて分割金型内で所定の形状に膨張させることにより、膨出部5と、アクスルケース6とを同時に形成するものである。   18 (a) to 18 (d) are process diagrams showing a method for manufacturing an integrated axle housing according to Embodiment 2 of the present invention. In this manufacturing method, a pipe material having a constant outer diameter is installed inside a split mold, and fluid pressure is applied to the inside of the pipe material to expand it into a predetermined shape in the split mold, thereby allowing the bulging portion 5 and the axle case 6 are formed simultaneously.

まず、図18(a)に示すように、所定の長さ、外径、肉厚を有するパイプ素材50を用意する。このパイプ素材50の外径は、完成した一体型アクスルハウジング2(2a)の小径部52の外径と略同じものとする。また、パイプ素材50の全長L1は、完成した一体型アクスルハウジング2(2a)の全長L2(図18(d)参照)よりも若干長いものとする。   First, as shown in FIG. 18 (a), a pipe material 50 having a predetermined length, outer diameter, and thickness is prepared. The outer diameter of the pipe material 50 is substantially the same as the outer diameter of the small diameter portion 52 of the completed integrated axle housing 2 (2a). The total length L1 of the pipe material 50 is slightly longer than the total length L2 (see FIG. 18 (d)) of the completed integrated axle housing 2 (2a).

次に、図18(b)に示すように、パイプ素材50を分割金型90の内部に設置する。この分割金型90は、例えば上型91と下型92とを備えた上下2つ割りの金型であり、その成形室93の形状が、完成した一体型アクスルハウジング2(2a)の全体形状と同一に造形されている。   Next, as shown in FIG. 18 (b), the pipe material 50 is installed inside the split mold 90. The split mold 90 is an upper and lower split mold having, for example, an upper mold 91 and a lower mold 92. The shape of the molding chamber 93 is the entire shape of the completed integrated axle housing 2 (2a). It is shaped identically.

成形室93は、一体型アクスルハウジング2(2a)のアクスルケース6の外径と同じ内径の円柱室94と、この円柱室94の中間に位置する膨張室95からなり、円柱室94の両側の外端部は外部に開放され、ここに一対の押圧ピストン96が密に、且つ円柱室94の長手方向に沿って摺動自在に挿入されている。   The molding chamber 93 includes a cylindrical chamber 94 having the same inner diameter as the outer diameter of the axle case 6 of the integrated axle housing 2 (2 a), and an expansion chamber 95 positioned between the cylindrical chambers 94. The outer end portion is opened to the outside, and a pair of pressing pistons 96 are inserted densely and slidable along the longitudinal direction of the cylindrical chamber 94.

そして、図18(c)に示すように、パイプ素材50の内部に流体圧力を加えると同時に、両側の押圧ピストン96でパイプ素材50の端面を軸方向に押圧し、膨張室95の内部でパイプ素材50の中間部を膨張させながらパイプ素材50を初期の長さL1から完成品の長さL2に短縮させる。これにより、図18(d)に示すように、膨出部5と左右一対のアクスルケース6とを同時に形成し、一体型アクスルハウジング2(2a)として完成させる。上記流体圧力としては、液圧や低温溶融金属の圧力等、多数考えられる。   As shown in FIG. 18 (c), fluid pressure is applied to the inside of the pipe material 50, and at the same time, the end surfaces of the pipe material 50 are pressed in the axial direction by the pressing pistons 96 on both sides, and the pipe is formed inside the expansion chamber 95. While expanding the intermediate portion of the material 50, the pipe material 50 is shortened from the initial length L1 to the length L2 of the finished product. Thus, as shown in FIG. 18 (d), the bulging portion 5 and the pair of left and right axle cases 6 are formed at the same time to complete the integrated axle housing 2 (2a). As the fluid pressure, a large number of fluid pressures, low-pressure molten metal pressures, and the like are conceivable.

この実施の形態2に係る一体型アクスルハウジングの製造方法によれば、単一の工程でパイプ素材50を一体型アクスルハウジング2(2a)の完成品にすることができるため、熟練を要することなく、非常に容易に一体型アクスルハウジング2(2a)を製造することができる。しかも、流体圧力により膨出部5を成形するため、通常のプレス成形では成形が困難な繊細な凹凸形状を比較的容易に形成することができる。   According to the method for manufacturing an integrated axle housing according to the second embodiment, the pipe material 50 can be made into a finished product of the integrated axle housing 2 (2a) in a single process, so that no skill is required. The integrated axle housing 2 (2a) can be manufactured very easily. In addition, since the bulging portion 5 is formed by fluid pressure, it is possible to relatively easily form a delicate concavo-convex shape that is difficult to form by ordinary press molding.

しかも、パイプ素材50の内部に流体圧力を加えて膨張室95の内部でパイプ素材50の中間部を膨張させると同時に、押圧ピストン96でパイプ素材50の端面を軸方向に押圧してパイプ素材50を初期の長さL1から完成品の長さL2に短縮させるので、パイプ素材50の中間部が膨張する際に肉厚が薄くなることが防止され、強度が低下することを効果的に防止することができる。
[一体型アクスルハウジングの製造方法の実施の形態3]
In addition, fluid pressure is applied to the inside of the pipe material 50 to expand the intermediate portion of the pipe material 50 inside the expansion chamber 95, and at the same time, the end surface of the pipe material 50 is pressed in the axial direction by the pressing piston 96. Is shortened from the initial length L1 to the length L2 of the finished product, so that when the intermediate portion of the pipe material 50 expands, it is prevented that the wall thickness is reduced, and the strength is effectively prevented from being reduced. be able to.
[Third Embodiment of Manufacturing Method of Integrated Axle Housing]

図19(a)〜(f)は、本発明の実施の形態3に係る一体型アクスルハウジングの製造方法を示す工程図である。この製造方法は、中間素材形成工程Fと、流体封入工程Gと、中央大径部設置工程Hと、膨出部成形工程Iと、開口部形成工程Jとを有している。   19 (a) to 19 (f) are process diagrams showing a method for manufacturing an integrated axle housing according to Embodiment 3 of the present invention. This manufacturing method includes an intermediate material forming step F, a fluid sealing step G, a central large diameter portion installation step H, a bulging portion forming step I, and an opening portion forming step J.

図19(a)に示すように、中間素材形成工程Fにおいて形成される中間素材97は、一体型アクスルハウジングの製造方法の実施の形態1で製造した第1中間素材53と同様に、所定の長さ、外径、肉厚を有するパイプ素材を塑性加工し、その中間部に位置する中央大径部51と、この中央大径部51の両側に位置し、中央大径部51の外径よりも小径な一対の小径部52とを有した形状である。   As shown in FIG. 19 (a), the intermediate material 97 formed in the intermediate material forming step F is the same as the first intermediate material 53 manufactured in the first embodiment of the manufacturing method of the integrated axle housing. A pipe material having a length, an outer diameter, and a wall thickness is plastically processed, and a central large-diameter portion 51 located in the middle portion thereof, and an outer diameter of the central large-diameter portion 51 located on both sides of the central large-diameter portion 51. A shape having a pair of small diameter portions 52 having a smaller diameter.

この中間素材97の形成方法は、前記実施の形態1の実施例1〜3と凡そ同様であるため、説明は省略するが、異なる点は、小径部52の両端部が液密に閉塞されて閉塞部98とされていることである。閉塞部98の閉塞方法は、例えば小径部52の両端をプレス成形して袋閉じにしたり、栓を圧入、嵌合、或いは固着すること等が考えられる。そして、中間素材97の全体の体積が、完成した一体型アクスルハウジング2(2a)の全体の体積に等しくなるように設定されている。   Since the method for forming the intermediate material 97 is substantially the same as the first to third embodiments of the first embodiment, the description is omitted. However, the difference is that both end portions of the small diameter portion 52 are liquid-tightly closed. That is, the closed portion 98 is used. As the closing method of the closing part 98, for example, both ends of the small diameter part 52 are press-molded to close the bag, or the stopper is press-fitted, fitted, or fixed. The entire volume of the intermediate material 97 is set to be equal to the entire volume of the completed integrated axle housing 2 (2a).

流体封入工程Gでは、図19(b)に示すように、圧力及び熱に耐え得る非圧縮性の流体(オイル等)99を中間素材97の内部に一杯に封入する。なお、中間素材97の一方の閉塞部98のみを閉塞し、流体99を封入してから他方の閉塞部98を閉塞する手順としてもよい。   In the fluid sealing step G, as shown in FIG. 19 (b), an incompressible fluid (oil or the like) 99 that can withstand pressure and heat is fully sealed inside the intermediate material 97. The procedure may be such that only one closing part 98 of the intermediate material 97 is closed, the fluid 99 is sealed, and then the other closing part 98 is closed.

図19(c)に示すように、中間素材97の成形に使用される金型100は、例えば上型101と下型102とを備えた上下2つ割りの金型であり、これら上型101と下型102とが型閉じされた時に内部に成形室103が画成され、この成形室103の内部容積Xが、中間素材97の全体の体積Yに一致し、且つ成形室103の内部形状が、完成した一体型アクスルハウジング2(2a)の形状と同一に設定されている。成形室103の一側には膨出部5の突出部25を形成するための凹部104等の凹凸形状が設けられている。中央大径部設置工程Hでは、図19(d)に示すように、分割金型100の成形室103に中間素材97を設置する。   As shown in FIG. 19 (c), the mold 100 used for molding the intermediate material 97 is, for example, an upper and lower split mold including an upper mold 101 and a lower mold 102. These upper mold 101 When the mold and the lower mold 102 are closed, a molding chamber 103 is defined. The inner volume X of the molding chamber 103 matches the entire volume Y of the intermediate material 97, and the inner shape of the molding chamber 103. Is set to be the same as the shape of the completed integrated axle housing 2 (2a). One side of the molding chamber 103 is provided with a concavo-convex shape such as a concave portion 104 for forming the protruding portion 25 of the bulging portion 5. In the central large diameter portion installation step H, an intermediate material 97 is installed in the molding chamber 103 of the split mold 100 as shown in FIG.

そして、膨出部成形工程Iでは、図19(e)の左半分に示すように分割金型100をプレス装置等に設置して型閉じすることにより、図19(e)の右半分に示すように中央大径部51を扁平化すると同時に、この扁平化した中央大径部51の片面を突出させて突出部25を形成する。   Then, in the bulging portion forming step I, as shown in the left half of FIG. 19 (e), the split mold 100 is installed in a press device or the like and closed to show the right half of FIG. 19 (e). In this way, the central large diameter portion 51 is flattened, and at the same time, one surface of the flattened central large diameter portion 51 is protruded to form the protruding portion 25.

つまり、分割金型100の型閉じ時には、成形室103内において略円筒形の中央大径部51が概ね扁平な形状に圧縮されるが、成形室103の内部容積Xと、中間素材97の全体の体積Yと、完成した一体型アクスルハウジング2(2a)の全体の体積とが等しく設定され、しかも中間素材97の内部に満たされた流体99が圧縮不可能である為、分割金型100の型閉じ時には、圧縮されない流体99が成形室103内の隅々まで流れようとし、この流体99の圧力により中間素材97の内面が内側から外側に向かって押圧され、これにより中央大径部51の片面が凹部104側に膨出変形して突出部25が形成される。同様に、他の部分も所定の形状に成形される。この成形後、中間素材97を分割金型100から取り出し、閉塞部98を切断する等して開放し、流体99を排出する。   That is, when the split mold 100 is closed, the substantially cylindrical central large-diameter portion 51 is compressed into a generally flat shape in the molding chamber 103, but the inner volume X of the molding chamber 103 and the entire intermediate material 97 are compressed. And the volume of the completed integral axle housing 2 (2a) is set to be equal, and the fluid 99 filled in the intermediate material 97 cannot be compressed. When the mold is closed, the uncompressed fluid 99 tends to flow to every corner in the molding chamber 103, and the pressure of the fluid 99 causes the inner surface of the intermediate material 97 to be pressed from the inside to the outside. One surface bulges and deforms toward the concave portion 104 to form a protruding portion 25. Similarly, other parts are also formed into a predetermined shape. After this molding, the intermediate material 97 is taken out from the divided mold 100, opened by cutting the closing portion 98 or the like, and the fluid 99 is discharged.

最後に、開口部形成工程Jとして、図19(f)に示すように、膨出部5の補強リング取付面21に開口部23が形成される。これと同時に、図5、図7等に示す開口部23周囲の前部挿通穴24と、膨出面22の後部挿通穴26とが形成され、これにより中央大径部51が差動装置8を収容する膨出部5として完成し、一体型アクスルハウジング2(2a)が完成する。   Finally, as an opening forming step J, an opening 23 is formed on the reinforcing ring mounting surface 21 of the bulging portion 5 as shown in FIG. At the same time, a front insertion hole 24 around the opening 23 shown in FIGS. 5 and 7 and a rear insertion hole 26 of the bulging surface 22 are formed. The bulging part 5 to be accommodated is completed, and the integrated axle housing 2 (2a) is completed.

この実施の形態3に係る一体型アクスルハウジングの製造方法によれば、中間素材97の内部に封入された流体99の非圧縮性を利用して、中間素材97の中央大径部51を扁平化すると同時に突出部25を突出成形できるため、高価な液圧プレス装置を用いることなく、液圧プレスと同等な優れた成形特性を得ることができる。   According to the method for manufacturing an integrated axle housing according to the third embodiment, the central large diameter portion 51 of the intermediate material 97 is flattened by utilizing the incompressibility of the fluid 99 enclosed in the intermediate material 97. At the same time, since the protruding portion 25 can be formed by protrusion, excellent forming characteristics equivalent to those of the hydraulic press can be obtained without using an expensive hydraulic press.

なお、流体封入工程Gにおいて、中間素材97の内部に非圧縮性の流体99を封入する代わりに軟質な低温溶融金属を充填し、常温のまま、あるいは加熱しながら膨出部成形工程Iにて分割金型100を型閉じし、上記低温溶融金属の持つ、流体99と同様な非圧縮性及び流動性により、アクスルハウジング2(2a)の成形を行い、その後、アクスルハウジング2(2a)の閉塞部98を開放してアクスルハウジング2(2a)加熱し、内部の低温溶融金属を溶融させて排出することにより、流体99を封入した場合と同様に一体型アクスルハウジング2(2a)を完成させることができる。   In the fluid filling step G, instead of filling the incompressible fluid 99 inside the intermediate material 97, a soft low-temperature molten metal is filled, and the bulging portion forming step I is performed at room temperature or while heating. The mold 100 is closed, and the axle housing 2 (2a) is molded by the same incompressibility and fluidity as the fluid 99 of the low-temperature molten metal, and then the axle housing 2 (2a) is closed. The axle housing 2 (2a) is heated by opening the portion 98, and the low-temperature molten metal inside is melted and discharged to complete the integrated axle housing 2 (2a) in the same manner as when the fluid 99 is sealed. Can do.

1 後輪懸架装置
2,2a 一体型アクスルハウジング
5 膨出部
6 アクスルケース
8 差動装置
9 軸受部
11 アクスル軸
21 補強リング取付面
22 膨出面
23 開口部
36,36a 補強リング
37,37a リング本体
38,38a 連結補強部材
44,44a 差動装置を補強リング取付面に締結するボルトである通しボルト
44b ボルト
50 パイプ素材
51 中央大径部
52 小径部
53 第1中間素材
55 扁平大径部
56 第2中間素材
77 分割金型
99 流体
103 成形室
A 第1中間素材形成工程
B 第2中間素材形成工程
C 開口部形成工程
D 膨出部成形工程
E 穴開け工程
F 中間素材形成工程
G 流体封入工程
H 中央大径部設置工程
I 膨出部成形工程
J 開口部形成工程
X 成形室の内部容積
Y 中間素材の体積
DESCRIPTION OF SYMBOLS 1 Rear wheel suspension apparatus 2,2a Integrated axle housing 5 Expansion part 6 Axle case 8 Differential device 9 Bearing part
11 Axle axle
21 Reinforcing ring mounting surface
22 Swelling surface
23 opening
36, 36a Reinforcing ring
37, 37a Ring body
38,38a Connecting reinforcement member
44,44a Through bolt that is a bolt that fastens the differential device to the reinforcing ring mounting surface
44b bolt
50 pipe material
51 Central large diameter part
52 Small diameter part
53 1st intermediate material
55 Flat large diameter part
56 Second intermediate material
77 split mold
99 fluid
103 Molding chamber A First intermediate material forming process B Second intermediate material forming process C Opening forming process D Swelling part forming process E Drilling process F Intermediate material forming process G Fluid sealing process H Center large diameter part installing process I Swelling Outlet forming process J Opening forming process X Internal volume of molding chamber Y Volume of intermediate material

Claims (10)

差動装置が収容される膨出部と、該膨出部から車幅方向両側に延びて内部にアクスル軸が軸支されるアクスルケースとを、閉断面を有する1本のパイプ素材を塑性加工することにより一体に形成した自動車用一体型アクスルハウジングであって、
前記膨出部は、前記差動装置が挿入される開口部を有する補強リング取付面と、この補強リング取付面に対向する膨出面とを有し、前記開口部に補強リングを介して前記差動装置のデフキャリアを固定し、前記補強リングは前記開口部の周囲に固着し、前記補強リングには、前記補強リング取付面と前記膨出面との間を連結する連結補強部材を設けたことを特徴とする自動車用一体型アクスルハウジング。
A pipe material having a closed cross section is plastically processed with a bulging portion in which the differential device is accommodated and an axle case extending from the bulging portion to both sides in the vehicle width direction and having an axle shaft supported therein. An integrated axle housing for automobiles formed integrally by
The bulging portion has a reinforcing ring mounting surface having an opening into which the differential device is inserted, and a bulging surface facing the reinforcing ring mounting surface, and the difference is inserted into the opening through the reinforcing ring. The differential carrier of the moving device is fixed, the reinforcing ring is fixed around the opening, and the reinforcing ring is provided with a connecting reinforcing member for connecting between the reinforcing ring mounting surface and the bulging surface. An integrated axle housing for automobiles.
前記補強リングは、前記開口部の周囲に固着される環状のリング本体を有し、該リング本体に前記連結補強部材が複数設けられ、前記補強リングの、前記連結補強部材が設けられている部分の間に雌ネジを形成し、前記差動装置を前記雌ネジにボルトで締結したことを特徴とする請求項1に記載の自動車用一体型アクスルハウジング。 The reinforcing ring has an annular ring main body fixed around the opening, and a plurality of the connecting reinforcing members are provided on the ring main body, and the portion of the reinforcing ring where the connecting reinforcing member is provided The automobile integrated axle housing according to claim 1 , wherein a female screw is formed between the two and the differential is fastened to the female screw with a bolt . 前記連結補強部材をパイプ状且つ車体前後方向に沿うように形成し、この連結補強部材に、前記差動装置を前記補強リング取付面に締結するボルトを挿通し、このボルトにより前記差動装置と前記補強リングと前記膨出部とを共締めしたことを特徴とする請求項1又は2に記載の自動車用一体型アクスルハウジング。 The connecting reinforcing member is formed in a pipe shape and along the longitudinal direction of the vehicle body, and a bolt for fastening the differential device to the reinforcing ring mounting surface is inserted into the connecting reinforcing member. The integrated axle housing for an automobile according to claim 1 or 2, wherein the reinforcing ring and the bulging portion are fastened together. 請求項1乃至3のいずれかに記載の自動車用一体型アクスルハウジングの製造方法であって、
所定の長さ、外径、肉厚を有するパイプ素材を塑性加工し、その中間部に位置する中央大径部と、該中央大径部の両側に位置し、該中央大径部の外径よりも小径な一対の小径部とを有する第1中間素材を形成する第1中間素材形成工程と、
前記第1中間素材の前記中央大径部を径方向に押圧することにより扁平化させて扁平大径部とした第2中間素材を形成する第2中間素材形成工程と、
前記第2中間素材の前記扁平大径部の前面に前記開口部を形成する開口部形成工程と、
前記扁平大径部の、前記開口部に対向する後面を、前記開口部から離反する方向に突出成形することにより、前記扁平大径部を前記膨出部として成形する膨出部成形工程と、
を備えてなることを特徴とする自動車用一体型アクスルハウジングの製造方法
A method for manufacturing an integrated axle housing for an automobile according to any one of claims 1 to 3,
A pipe material having a predetermined length, outer diameter, and thickness is plastically processed, and a central large-diameter portion located in the middle portion thereof, and an outer diameter of the central large-diameter portion located on both sides of the central large-diameter portion. A first intermediate material forming step of forming a first intermediate material having a pair of smaller diameter parts having a smaller diameter,
A second intermediate material forming step of forming a second intermediate material flattened by pressing the central large diameter portion of the first intermediate material in a radial direction;
An opening forming step of forming the opening on the front surface of the flat large diameter portion of the second intermediate material;
A bulging portion forming step of forming the flat large diameter portion as the bulging portion by projecting and molding a rear surface of the flat large diameter portion facing the opening in a direction away from the opening;
Method of manufacturing an automotive integrated axle housing you characterized in that it comprises a.
前記第1中間素材形成工程において、前記塑性加工をする前の前記パイプ素材の外径を前記中央大径部の外径に略一致させ、このパイプ素材を、その両端から中央部に向かって縮径し、中央部は縮径させないでおくことにより、前記第1中間素材の中央部に前記中央大径部を形成し、その両側に前記小径部を形成することを特徴とする請求項4に記載の自動車用一体型アクスルハウジングの製造方法。 In the first intermediate material forming step, the outer diameter of the pipe material before the plastic working is substantially matched with the outer diameter of the central large diameter portion, and the pipe material is reduced from both ends toward the central portion. and size, by the central unit Prefer not reduced in diameter, the Ang-diameter portion formed in a central portion of the first intermediate material, in claim 4, characterized by forming the small-diameter portion on both sides The manufacturing method of the integrated axle housing for motor vehicles of description . 前記第1中間素材形成工程において、前記塑性加工をする前の前記パイプ素材の外径を前記小径部の外径に略一致させ、このパイプ素材を、その一端から所定の長さまで拡径した後、この拡径した部分を前記一端から前記所定の長さよりも手前まで縮径することにより、前記第1中間素材の中央部に前記中央大径部を形成し、その両側に前記小径部を形成することを特徴とする請求項に記載の自動車用一体型アクスルハウジングの製造方法。 In the first intermediate material forming step, after the outer diameter of the pipe material before the plastic working is substantially matched with the outer diameter of the small diameter portion, the pipe material is expanded from one end thereof to a predetermined length. Then, by reducing the diameter of the expanded portion from the one end to a position shorter than the predetermined length, the central large diameter portion is formed in the central portion of the first intermediate material, and the small diameter portions are formed on both sides thereof. The method of manufacturing an integrated axle housing for an automobile according to claim 4 . 前記第1中間素材形成工程において、前記塑性加工をする前の前記パイプ素材の外径を前記小径部の外径に略一致させ、該パイプ素材を金型の内部に設置し、該パイプ素材の内部に流体圧力を加えて前記金型内で所定の形状に膨張させることにより前記中央大径部を形成することを特徴とする請求項に記載の自動車用一体型アクスルハウジングの製造方法。 In the first intermediate material forming step, the outer diameter of the pipe material before the plastic working is substantially matched with the outer diameter of the small diameter portion, the pipe material is installed inside a mold, 5. The method for manufacturing an integrated axle housing for an automobile according to claim 4 , wherein the central large diameter portion is formed by applying fluid pressure to the inside of the mold so as to expand into a predetermined shape . 前記膨出部成形工程において、前記扁平大径部を、その後面側から所定の凹み形状を有する凹金型に設置し、前記扁平大径部の前面に形成した開口部から所定の凸形状を有する凸金型を突き込むことにより、前記扁平大径部の後面を前記凹金型の前記凹み形状内に陥没させて突出部を形成することを特徴とする請求項に記載の自動車用一体型アクスルハウジングの製造方法。 In the bulging portion forming step, the flat large diameter portion is installed in a concave mold having a predetermined concave shape from the rear surface side, and a predetermined convex shape is formed from an opening formed on the front surface of the flat large diameter portion. 5. The automobile part according to claim 4 , wherein by projecting a convex mold having the concave mold, the rear surface of the flat large-diameter part is recessed into the concave shape of the concave mold to form a protruding part. Manufacturing method of body type axle housing. 請求項1乃至3のいずれかに記載の自動車用一体型アクスルハウジングの製造方法であって、
所定の長さ、外径、肉厚を有するパイプ素材を金型の内部に設置し、該パイプ素材の内部に流体圧力を加えて該パイプ素材を前記金型内で所定の形状に膨張させることにより、前記膨出部と前記アクスルケースとを同時に形成することを特徴とする自動車用一体型アクスルハウジングの製造方法。
A method for manufacturing an integrated axle housing for an automobile according to any one of claims 1 to 3,
A pipe material having a predetermined length, outer diameter, and thickness is installed inside a mold, and fluid pressure is applied to the inside of the pipe material to expand the pipe material into a predetermined shape in the mold. Accordingly, the bulge portion and the manufacturing process of automobiles for integral axle housing you and forming the axle case at the same time.
請求項1乃至3のいずれかに記載の自動車用一体型アクスルハウジングの製造方法であって、
所定の長さ、外径、肉厚を有するパイプ素材を塑性加工し、その中間部に位置する中央大径部と、該中央大径部の両側に位置し、該中央大径部の外径よりも小径な一対の小径部とを有し、該小径部の両端部は閉塞され、且つその全体の体積が、完成した一体型アクスルハウジングの全体の体積に等しい中間素材を形成する中間素材形成工程と、
前記中間素材の内部に非圧縮性の流体を一杯に封入する流体封入工程と、
型閉じ時における成形室の内部容積が前記中間素材の全体の体積に等しい分割金型の、前記成形室に前記中間素材を設置する中間素材設置工程と、
前記分割金型を型閉じすることにより、前記中間素材の前記中央大径部を扁平化すると同時に所定部分を突出させ、これにより前記中央大径部を前記膨出部として成形する膨出部成形工程と、
前記膨出部の前面に前記開口部を形成する開口部形成工程と、
を備えてなることを特徴とする自動車用一体型アクスルハウジングの製造方法。
A method for manufacturing an integrated axle housing for an automobile according to any one of claims 1 to 3,
A pipe material having a predetermined length, outer diameter, and thickness is plastically processed, and a central large-diameter portion located in the middle portion thereof, and an outer diameter of the central large-diameter portion located on both sides of the central large-diameter portion. An intermediate material forming an intermediate material having a pair of smaller diameter parts having a smaller diameter, both ends of the small diameter part being closed, and an overall volume of which is equal to the entire volume of the completed integrated axle housing Process,
A fluid sealing step for fully filling an incompressible fluid inside the intermediate material;
An intermediate material installation step of installing the intermediate material in the molding chamber of a split mold in which the internal volume of the molding chamber when the mold is closed is equal to the entire volume of the intermediate material;
By closing the split mold, the central large-diameter portion of the intermediate material is flattened and at the same time a predetermined portion is projected, thereby forming the central large-diameter portion as the bulging portion. Process,
An opening forming step of forming the opening on the front surface of the bulging portion;
A method for manufacturing an integrated axle housing for automobiles.
JP2009091213A 2009-04-03 2009-04-03 Integrated axle housing for automobile and method for manufacturing the same Expired - Fee Related JP5466419B2 (en)

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