HOLLOW SPRING AND METHOD OF MANUFACTURING THE SAME

Abstract

A method includes, providing a tubular member (10) used for a hollow spring, and applying the compressive residual stress to at least a portion of an inner surface of the steel tube by applying the compressive force to at least a portion of an outer surface of the tubular member (10) from a circumferential direction, and a fatigue life of the tubular member (10) is prolonged by applying the compressive residual stress to the inner surface of the tubular member (10). Applying the force to the outer surface of the tubular member (10) includes pressing the tubular member (10) with a die (1). The die (1) has a pressing surface (1a) shaped such that the compressive force can be applied to at least the portion of the outer surface of the tubular member (10) from the circumferential direction.

Claims

1. A hollow spring comprising: a steel tube, wherein at least a portion of an inner surface of the steel tube has compressive residual stress directed in an axial direction of the steel tube in order to reduce tensile stress directed in the axial direction of the steel tube that occurs when a load is applied to the steel tube, wherein the at least the portion comprises an inner surface of a specific portion of the steel tube at which the tensile stress is concentrated when the load is applied to the hollow spring.

2. (canceled)

3. The hollow spring according to claim 1, wherein the hollow spring is a stabilizer, and the at least the portion includes a bending portion of the steel tube constituting the stabilizer.

4. A method of manufacturing a hollow spring, comprising: providing a steel tube used for the hollow spring; and applying compressive force to at least a portion of an outer surface of the steel tube from a circumferential direction to apply compressive residual stress to at least a portion of an inner surface of the steel tube; wherein a fatigue life of the steel tube is prolonged by applying the compressive residual stress to the inner surface of the steel tube.

5. The method according to claim 4, wherein applying the compressive force to the outer surface of the steel tube comprises pressing the steel tube with a die.

6. The method according to claim 5, wherein the die comprises a pressing surface shaped such that the compressive force can be applied to the at least the portion of the outer surface of the steel tube from the circumferential direction.

7. The method according to claim 6, wherein the pressing surface extends in the circumferential direction along the outer surface of the steel tube.

8. The method according to claim 7, wherein the pressing surface extends in the circumferential direction of the steel tube over a half of a circumference.

9. The method according to claim 6, wherein the pressing surface includes a round shape and faces the outer surface of the steel tube in an axial direction of the steel tube.

10. The method according to claim 5, wherein the steel tube pressed with the die is supported by a flat surface.

11. The method according to claim 4, wherein the steel tube is subjected to bending processing to have a predetermined shape.

12. The method according to claim 4, wherein the steel tube is subjected to a heat treatment.

13. The hollow spring manufactured by the method according to claim 4.

14. The method according to claim 7, wherein the pressing surface includes a round shape and faces the outer surface of the steel tube in an axial direction of the steel tube.

15. The method according to claim 8, wherein the pressing surface includes a round shape and faces the outer surface of the steel tube in an axial direction of the steel tube.

16. The method according to claim 6, wherein the steel tube pressed with the die is supported by a flat surface.

17. The method according to claim 7, wherein the steel tube pressed with the die is supported by a flat surface.

18. The method according to claim 8, wherein the steel tube pressed with the die is supported by a flat surface.

19. The method according to claim 9, wherein the steel tube pressed with the die is supported by a flat surface.

20. The method according to claim 5, wherein the steel tube is subjected to bending processing to have a predetermined shape.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] FIG. 1 is a flowchart illustrating a series of processes of manufacturing a hollow spring.

[0018] FIG. 2 is a three-view drawing showing a tubular member.

[0019] FIG. 3 is a perspective view showing a method of manufacturing a hollow spring applied to a straight portion of a tubular member.

[0020] FIG. 4 is a side view showing a method of manufacturing a hollow spring applied to a straight portion of a tubular member.

[0021] FIG. 5 is a cross sectional view showing a method of manufacturing a hollow spring applied to a straight portion of a tubular member.

[0022] FIG. 6 is a perspective view showing the distribution of the minimum principal stress on an inner surface of a straight portion of a tubular member subjected to the compression processing.

[0023] FIG. 7 is a graph showing results obtained by performing a fatigue test.

[0024] FIG. 8 is a perspective view showing a method of manufacturing a hollow spring applied to a bending portion of a tubular member.

[0025] FIG. 9 is a top view illustrating a method of manufacturing a hollow spring applied to a bending portion of a tubular member.

[0026] FIG. 10 is a cross sectional view showing a method of manufacturing a hollow spring applied to a bending portion of a tubular member.

[0027] FIG. 11 is a perspective view showing the distribution of the minimum principal stress on an inner surface of a bending portion of a tubular member subjected to the compression processing.

[0028] FIG. 12 is a top view showing the distribution of the magnitude of the maximum principal stress generated when a load is applied to a tubular member.

[0029] FIG. 13 is a partially enlarged perspective view showing the distribution of the magnitude of the maximum principal stress at a bending portion of the tubular member of FIG. 12.

[0030] FIG. 14 is a perspective view showing the distribution of the maximum principal stress on an inner surface of the bending portion of FIG. 13.

EMBODIMENTS OF THE INVENTION

[0031] Hereinafter, an embodiment of a hollow spring and a method of manufacturing the hollow spring will be described in detail with reference to the drawings. The hollow spring of the present embodiment is composed of a steel tube, and the fatigue strength of the hollow spring is enhanced by applying compressive force to an outer surface of the steel tube from a circumferential direction to impart compressive residual stress to an inner surface of the steel tube.

[0032] In the present embodiment, descriptions will be given by assuming that a hollow stabilizer is the hollow spring. The hollow spring of the present embodiment corresponds to a main body of the hollow stabilizer obtained by excluding portions for connecting with other members formed at end portions from the entire hollow stabilizer. The hollow spring of the present embodiment is not limited to the hollow stabilizer, and can be applied to other types of hollow springs such as, for example, hollow coil springs for automobile suspensions.

[0033] As shown in the flowchart of FIG. 1, the hollow stabilizer is manufactured through a series of processes of receiving (step S1) and cutting (step S2) the steel tube of a raw material, and of applying, to the steel tube of the raw material, bending processing (step S3), a heat treatment (step S4), compression processing (step S5), end portion processing (step S6), shot peening (step S7), and painting (step S8).

[0034] The method of manufacturing the hollow spring of the present embodiment corresponds to the process of the compression processing of step S5. In the method of manufacturing the hollow spring of the present embodiment, the steel tube subjected to the processes of the reception (step S1), cutting (step S2), the bending processing (step S3), and the heat treatment (step S4) is provided, and the compression processing is applied to the steel tube (step S5). The compression processing (step S5) may be performed after the process of the end portion processing (step S6) instead of being performed immediately after the process of the heat treatment (step S4).

[0035] Although an order will be different from the order shown in FIG. 1, in the manufacturing process of the hollow stabilizer, the end portion processing (step S6) may be performed before the heat treatment (step S4). Even in the above case, the compression processing (step S5) is performed following the heat treatment (step S4).

[0036] In the following description, a steel tube which is subjected to the processes of steps S1 to S4 of FIG. 1 and thereafter is applied with the method of manufacturing the hollow spring of the present embodiment corresponding to the process of step S5 is referred to as a tubular member for convenience.

[0037] FIG. 2 is a three-view drawing showing the tubular member 10. FIG. 2(a) is a top view, FIG. 2(b) is a front view, and FIG. 2(c) is a side view. The tubular member 10 is formed to have substantially a shape of C that is inverted to face leftward by performing the bending processing, and has a first bending portion 13 in the vicinity of a first end 11 and a second bending portion 14 in the vicinity of a second end 12, and further includes a straight portion in addition to the first bending portion 13 and the second bending portion 14.

[0038] As the method of manufacturing the hollow spring of the present embodiment, a method of performing the compression processing to the tubular member 10 by pressing a die will be described. In the present embodiment, descriptions will be given for each of the straight portion and the bending portion of the tubular member 10 separately.

[0039] First, a case will be described in which the present embodiment is applied to the straight portion of the tubular member 10. FIGS. 3 to 5 are diagrams showing the method of manufacturing the hollow spring of the present embodiment applied to the straight portion of the tubular member 10. FIG. 3 is a perspective view, FIG. 4 is a side view, and FIG. 5 is a cross sectional view taken along a cross section V-V of FIG. 4.

[0040] The straight portion of the tubular member 10 is supported by a flat top surface of a table that extends substantially horizontally (not shown). At a predetermined position of the tubular member 10 in an axial direction, the die 1 is arranged so as to cover a predetermined width in the axial direction of an upper half portion of the tubular member 10.

[0041] The die 1 has a pressing surface 1a shaped such that the compressive force can be applied to at least a part of the outer surface of the tubular member 10 from the circumferential direction. More specifically, the pressing surface 1a extends in the circumferential direction along the outer surface of the tubular member 10 and reaches a half of a circumference in the circumferential direction so as to cover the upper half portion of the tubular member 10. Further, the die 1 has a pressing surface 1a with a round shape which faces and comes into contact with the outer surface of the tubular member 10 in the axial direction. The die 1 may be made of tool steel.

[0042] Pressing such the die 1 causes the compressive force to be applied to the tubular member 10 from the circumferential direction so that the compression processing is performed on the tubular member 10. As shown in FIG. 5, the pressing surface 1a with the round shape of the die 1 contacts with a predetermined range of the outer surface of the tubular member 10 in a cross section extending in a radial direction of the tubular member 10. The range of the outer surface of the tubular member 10 contacting the pressing surface 1a extends to the upper half portion of the tubular member 10 in the circumferential direction, and an entire range in which the pressing surface 1a contacts the outer surface of the tubular member 10 forms an upper semicircle extending along the outer surface of the tubular member 10 in a plane orthogonal to an axis of the tubular member 10.

[0043] If the die 1 is pressed in such the state, the compressive force is applied to the tubular member 10 from the circumferential direction, and the deformation in the axial direction of the tubular member 10 is caused in the vicinity of an range of the inner surface of the tubular member 10 corresponding to the range where the pressing surface 1a of the die 1 contacts the outer surface, but the displacement is constrained by surrounding materials. Therefore, when the pressing load of the die 1 is removed, the compressive residual stress is applied to the inner surface of the tubular member 10 in the axial direction.

[0044] FIG. 6 is a perspective view showing the distribution of the minimum principal stress on the inner surface of the straight portion of the tubular member 10 applied with the compression processing. The distribution of the minimum principal stress is calculated based on a finite element method. The minimum principal stress in this case corresponds to the compressive stress which is a negative value. It was confirmed that the minimum principal stress was remained after the removal of the pressing load of the die 1, and thus, it became clear that the compressive residual stress was applied to the inner surface. As can be seem from arrows in FIG. 6, it can be observed that the minimum principal stress generally points in the axial direction of the tubular member 10.

[0045] Effects on the straight portion of the tubular member 10 by performing the compression processing was confirmed by performing experiments. A steel tube subjected to the heat treatment was used as a target object of the compression processing. The steel tube had an outer diameter of 28.6 mm, the thickness of 4 mm, and the length of 300 mm. In the experiment, a strain gauge was attached to the inner surface of the steel tube, and the residual stress was calculated from the strain detected on the inner surface of the steel tube before and after performing the compression processing.

[0046] Table 1 shows experimental results of the relationship among the load applied to the die 1, the strain and the residual stress. In Table 1, values in a column “during compression” are values obtained by applying the load to the press, and alternatively, values in a column “time of release” are values obtained by removing the load from the press.

TABLE-US-00001 TABLE 1 STRAIN (με) STRESS (MPa) APPLIED DURING TIME OF DURING TIME OF LOAD (N) COMPRESSION RELEASE COMPRESSION RELEASE 101640 −925 −32 −190.55 −6.592 127050 −1367 −257 −281.6 −52.942 152460 −2314 −1222 −476.68 −251.73 177870 −3261 −2187 −671.77 −450.52 203280 −4208 −3152 −866.85 −649.31

[0047] As shown in Table 1, the stress of the inner surface of the steel tube took negative values in a column of “Time of release” at which the load was removed from the press and it was observed that the compressive residual stress was imparted on the inner surface of the steel tube by performing the compression processing. Further, it was observed that, as the applied load increases, the stress of the negative value of the inner surface of the steel tube at the time of release further decreases, and as the compressive force applied during the compression processing increases, the compressive residual stress further increases.

[0048] Furthermore, the effect of the compressive residual stress applied to the straight portion of the tubular member 10 was confirmed by performing a 4-point bending fatigue test. As a target object for performing the fatigue test, used is the steel tube which was used as the target object in the experiment of the compression processing, and is subjected to the compression processing by using the press of 152460 N among the loads shown in Table 1 under the same condition as in the experiment of the compression processing.

[0049] Table 2 shows the results obtained by performing the fatigue test for each of two target objects that are one target object subjected to the compression processing and the other target object not subjected to the compression processing. FIG. 7 shows the results obtained by performing the fatigue test shown in Table 2 in a graph, and the graph has a horizontal axis representing the number of endurance and a vertical axis representing the applied stress. In FIG. 7, data point A represents the steel tube not subjected to the compression processing, and alternatively, data point B represents the steel tube subjected to the compression processing.

TABLE-US-00002 TABLE 2 APPLIED NUMBER OF STRESS (MPa) ENDURANCE COMPRESSION PROCESSING 720 551000 NOT PERFORMED 684 848000 COMPRESSION PROCESSING 792 126000 PERFORMED 756 616000

[0050] The graph in FIG. 7 shows, in a range in the vicinity of the number of endurance where the fatigue test was performed, two data points A representing the steel tube subjected to the compression processing and alternatively two data points B representing the steel tube not subjected to the compression processing, and each of the two data points A and the data points B are connected each other and extended to form a linear relationship between the number of endurance and the applied stress of the graph. With reference to the above, in both cases of the steel tube subjected to the compression processing and the steel tube not subjected to the compression processing, it was observed that, as the applied pressure increases, the number of endurance decreased more. On the other hand, it was observed that the number of endurance corresponding to the same applied stress was significantly increased in the case of the steel tube subjected to the compression processing than in the case of the steel tube not subjected to the compression processing. This clarified that the fatigue life of the tubular member is prolonged by applying the compression processing to the tubular member to impart the compressive residual stress to the inner surface.

[0051] Next, a case will be described in which the present embodiment is applied to the bending portions of the tubular member 10. FIGS. 8 to 10 are diagrams showing the method of manufacturing the hollow spring of the present embodiment applied to the bending portions of the tubular member 10. FIG. 8 is a perspective view, FIG. 9 is a top view, and FIG. 10 is a cross sectional view taken along a cross section X-X of FIG. 9.

[0052] The bending portion of the tubular member 10 is supported by a flat top surface of a table extending substantially horizontally (not shown). At a predetermined position of the tubular member 10 in the axial direction, a die 1 is arranged so as to cover a predetermined range of the upper half portion of the tubular member 10 in the axial direction. The die 1 applied to the bending portion of the tubular member 10 may have a shape different from that of the die 1 applied to the straight portion of the tubular member 10 described above, but in order to clarify the correspondence relationship between them, descriptions are given by denoting them with a common reference numeral.

[0053] The die 1 has the pressing surface 1a shaped such that the compressive force can be applied to at least a part of the outer surface of the tubular member 10 from the circumferential direction. More specifically, the pressing surface 1a extends in the circumferential direction along the outer surface of the tubular member 10 and reaches a half of a circumference in the circumferential direction so as to cover the upper half portion of the tubular member 10. Further, the die 1 has the pressing surface 1a of a round shape which faces and contacts the outer surface of the tubular member 10 in the axial direction of the tubular member 10. The pressing surface 1a of the die 1 may be formed of tool steel.

[0054] Pressing such the die 1 causes the compressive force to be applied to the tubular member 10 from the circumferential direction so that the compression processing is performed to the tubular member 10. In the case of the bending portion of the tubular member 10 also, similarly to the case of the straight portion shown in FIG. 5, the pressing surface 1a with the round shape of the die 1 contacts a predetermined range of the outer surface of the tubular member 10 in a cross section extending in a radial direction of the tubular member 10. As shown in FIG. 10, the range of the outer surface of the tubular member 10 contacting the pressing surface 1a extends to the upper half portion of the tubular member 10 in the circumferential direction, and an entire range in which the pressing surface 1a contacts the outer surface of the tubular member 10 forms an upper semicircle extending along the outer surface of the tubular member 10 in a plane orthogonal to an axis of the tubular member 10.

[0055] If the die 1 is pressed in such the state, the compressive force is applied to the tubular member 10 from the circumferential direction, and the deformation in the axial direction of the tubular member 10 is caused in the vicinity of an range of the inner surface of the tubular member 10 corresponding to the range where the pressing surface 1a of the die 1 contacts the outer surface, but the displacement is constrained by surrounding materials. Therefore, when the pressing load of the die 1 is removed, compressive residual stress is imparted to the inner surface of the tubular member 10 in the axial direction.

[0056] FIG. 11 is a perspective view showing the distribution of the minimum principal stress on the inner surface of the bending portion of the tubular member 10 subjected to the compression processing. The distribution of the minimum principal stress is calculated based on a finite element method. The minimum principal stress in this case corresponds to the compressive stress which is a negative value. It was confirmed that the minimum principal stress was remained after the removal of the pressing load of the die 1, and thus, it became clear that the compressive residual stress was imparted to the inner surface. As can be seen from arrows in FIG. 11, it can be observed that the minimum principal stress generally point in the axial direction of the tubular member 10.

[0057] FIG. 12 is a top view showing the distribution of the magnitude of the maximum principal stress generated when the load is applied to the tubular member 10. In FIG. 12, the distribution of the magnitude of the maximum principal stress generated when the load is applied between the first end 11 and the second end 12 of the tubular member 10 is obtained based on the finite element method. The maximum principal stress in this case corresponds to the tensile stress which is a positive value. FIG. 12 shows that as a color of an area is dark, the maximum principal stress is larger, and thus, in a black area, the maximum principal stress is the largest, and alternatively, in a white area, the maximum principal stress is the smallest. From FIG. 12, it can be observed that the maximum principal stress is the largest at a first bending portion 13 in the vicinity of the first end 11.

[0058] FIG. 13 is a partially enlarged perspective view showing the distribution of the magnitude of the maximum principal stress at the first bending portion 13 of the tubular member 10 of FIG. 12. From FIG. 13, it can be observed that an area of the first bending portion 13, in which the maximum principal stress is large, generally extends along the axial direction of the tubular member 10.

[0059] FIG. 14 is a diagram showing the distribution of the maximum principal stress at the first bending portion 13 of FIG. 13. The distribution of the maximum principal stress is calculated based on the finite element method. The maximum principal stress in this case also corresponds to the tensile stress which is a positive value. As shown by arrows in FIG. 14, it is observed that a direction of the maximum principal stress generally points in the axial direction of tubular member 10.

[0060] With reference to the distribution of the minimum principal stress on the inner surface of the bending portion of the tubular member 10 subjected to the compression processing shown in FIG. 11, the minimum principal stress at the bending portion corresponding to the compressive residual stress imparted by performing the compression processing is approximately directed in the axial direction of the tubular member 10. The maximum principal stress corresponding to the tensile stress of the tubular member 10 generated when the load is applied to the tubular member as shown in FIGS. 13 and 14 is approximately directed in the same axial direction as the direction of the minimum principal stress. Accordingly, the compressive residual stress of the negative value corresponding to the minimum principal stress can reduce the tensile stress which is the positive value corresponding to the maximum principal stress.

[0061] Therefore, by performing the compression processing and imparting the compressive residual stress, to a portion of the tubular member 10 at which the large tensile stress is caused when being applied with a load, such as the first bending portion 13, the caused tensile stress is reduced, and accordingly the tensile stress can be relieved. This reduces the load imposed on the inner surface of the tubular member 10 due to the tensile stress, and accordingly, the fatigue life of the tubular member 10 can be prolonged.

[0062] As described above, according to the present embodiment, the compressive residual stress is applied to the inner surface of the tubular member 10 configuring the hollow spring, and accordingly, the fatigue life of the tubular member 10 can be prolonged. Specifically, pressing the die 1 enables the compressive residual stress to be imparted to the inner surface of a desired portion regardless of whether the portion is the straight portion or the bending portion of the tubular member 10. The compressive residual stress can be sufficiently imparted by pressing the die 1, and thus, a complicated equipment configuration or the like is not required.

[0063] Further, the compressive residual stress can be applied to the inner surface of a specific portion such as the bending portion at which the tensile stress concentrates and becomes the high stress when a load is applied to a hollow stabilizer. This enables the reduction in the tensile stress at the high stress portion by the compressive residual stress to prolong the fatigue life. Further, the compressive residual stress can be imparted to the bending portion of the tubular member 10 such that the direction of the minimum principal stress corresponding to the compressive residual stress matches the direction of the maximum principal stress corresponding to the tensile stress.

INDUSTRIAL APPLICABILITY

[0064] The present invention can be applied to a hollow spring used for a vehicle such as an automobile and a method of manufacturing the hollow spring.

DESCRIPTION OF REFERENCE NUMERALS

[0065] 1 die [0066] 1a Pressing surface [0067] 10 Tubular member [0068] 11 First end [0069] 12 Second end [0070] 13 First bending portion [0071] 14 Second bending portion