Fixed type constant velocity universal joint

Abstract

An outer joint member includes a cutout portion that is formed at least at each corner portion on an opening side of a cup section, which is defined between a radially inner opening end portion of each of track grooves and a radially inner spherical surface portion formed between the track grooves. The cutout portion is configured to prevent a cage from interfering with the outer joint member when the cage is incorporated into the outer joint member. The cutout portion and the track grooves of the outer joint member are finished by cold-forging ironing using a single ironing punch.

Claims

1. A fixed type constant velocity universal joint, comprising: an outer joint member comprising a cup section having a plurality of track grooves formed in a radially inner surface thereof; an inner joint member having a plurality of track grooves formed in a radially outer surface thereof; a plurality of torque transmitting balls, which are interposed between the plurality of track grooves of the outer joint member and the plurality of track grooves of the inner joint member, and are configured to transmit torque therebetween; and a cage, which is interposed between the radially inner surface of the outer joint member and the radially outer surface of the inner joint member, the cage comprising pockets configured to retain the plurality of torque transmitting balls therein, the outer joint member further comprising a cutout portion that is formed at least at each corner portion on an opening side of the cup section, which is defined between a radially inner opening end portion of each of the plurality of track grooves and a radially inner spherical surface portion formed between the plurality of track grooves, the cutout portion being configured to prevent the cage from interfering with the outer joint member when the cage is incorporated into the outer joint member, and in a forging state of the outer joint member, the cutout portions and the plurality of track grooves of the outer joint member are cold-forging ironing finished using a single ironing punch.

2. The fixed type constant velocity universal joint according to claim 1, wherein the cutout portions are formed into a round shape.

3. The fixed type constant velocity universal joint according to claim 2, further comprising connecting portions formed between the cutout portions and the track grooves, wherein the connecting portions are formed into a round shape.

4. The fixed type constant velocity universal joint according to claim 2, further comprising: a cup-inlet chamfer formed along an entire periphery of an opening portion of the cup section; and a track-inlet chamfer formed at a boundary portion between each of the plurality of track grooves and the cup-inlet chamfer, wherein the plurality of track grooves and the track-inlet chamfers are formed by cold-forging finishing.

5. The fixed type constant velocity universal joint according to claim 1, further comprising connecting portions formed between the cutout portions and the track grooves, wherein the connecting portions are formed into a round shape.

6. The fixed type constant velocity universal joint according to claim 5, further comprising a track chamfer formed at a boundary portion between each of the plurality of track grooves and the radially inner spherical surface portion formed between the plurality of track grooves of the outer joint member, wherein the track chamfers and the track grooves are continuously formed through intermediation of the connecting portions having the round shape.

7. The fixed type constant velocity universal joint according to claim 6, further comprising: a cup-inlet chamfer formed along an entire periphery of an opening portion of the cup section; and a track-inlet chamfer formed at a boundary portion between each of the plurality of track grooves and the cup-inlet chamfer, wherein the cup-inlet chamfer and the track-inlet chamfers are formed by cold-forging finishing.

8. The fixed type constant velocity universal joint according to claim 5, further comprising: a cup-inlet chamfer formed along an entire periphery of an opening portion of the cup section; and a track-inlet chamfer formed at a boundary portion between each of the plurality of track grooves and the cup-inlet chamfer, wherein the cup-inlet chamfer and the track-inlet chamfers are formed by cold-forging finishing.

9. The fixed type constant velocity universal joint according to claim 5, further comprising: a cup-inlet chamfer formed along an entire periphery of an opening portion of the cup section; and a track-inlet chamfer formed at a boundary portion between each of the plurality of track grooves and the cup-inlet chamfer, wherein the plurality of track grooves and the track-inlet chamfers are formed by cold-forging finishing.

10. The fixed type constant velocity universal joint according to claim 1, wherein the fixed type constant velocity universal joint comprises a fixed type undercut-free constant velocity universal joint, in which a bottom surface of each of the plurality of track grooves of the outer joint member and a bottom surface of each of the plurality of track grooves of the inner joint member each comprise a circular-arc portion and a straight portion.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 is a perspective view of a main part of an outer joint member of a fixed type constant velocity universal joint according to an embodiment of the present invention.

(2) FIG. 2 is a longitudinal sectional view of a main part of the fixed type constant velocity universal joint according to the embodiment of the present invention adopting the outer joint member illustrated in FIG. 1.

(3) FIG. 3 is a transverse sectional view of a main part of the fixed type constant velocity universal joint illustrated in FIG. 2.

(4) FIG. 4 is a front view for illustrating a step of incorporating a cage into the outer joint member.

(5) FIG. 5 is a sectional view taken along the line D-D of FIG. 4.

(6) FIG. 6 is a sectional view taken along the line E-E of FIG. 4.

(7) FIG. 7 is a perspective view of a track-inlet chamfer.

(8) FIG. 8 is a schematic view of a main part of a forging apparatus.

(9) FIG. 9 is a side view of an ironing punch of the forging apparatus.

(10) FIG. 10 is a perspective view of the ironing punch of the forging apparatus.

(11) FIG. 11A is an end view of track grooves when viewed from a radially inner side, for illustrating the outer joint member having a radially inner surface in which the track grooves, cage incorporating chamfers (cutout portions) extending along entire lengths of the track grooves, and connecting portions are formed.

(12) FIG. 11B is a perspective view of the track grooves when viewed from the radially inner side, for illustrating the outer joint member having the radially inner surface in which the track grooves, the cage incorporating chamfers (cutout portions) extending along the entire lengths of the track grooves, and the connecting portions are formed.

(13) FIG. 12A is an end view of the track grooves when viewed from the radially inner side, for illustrating the outer joint member having the radially inner surface in which the cage incorporating chamfers (cutout portions) are formed on the joint opening portion side.

(14) FIG. 12B is a perspective view of the track grooves when viewed from the radially inner side, for illustrating the outer joint member having the radially inner surface in which the cage incorporating chamfers (cutout portions) are formed on the joint opening portion side.

(15) FIG. 13A is an end view of the track grooves when viewed from the radially inner side, for illustrating the outer joint member having the radially inner surface in which the track grooves, the cage incorporating chamfers (cutout portions), and the connecting portions are formed.

(16) FIG. 13B is a perspective view of the track grooves when viewed from the radially inner side, for illustrating the outer joint member having the radially inner surface in which the track grooves, the cage incorporating chamfers (cutout portions), and the connecting portions are formed.

(17) FIG. 14 is a sectional view of a related-art fixed type undercut-free constant velocity universal joint.

(18) FIG. 15 is a front view for illustrating a step of incorporating a cage into an outer joint member of the related-art fixed type constant velocity universal joint.

(19) FIG. 16 is a sectional view taken along the line A-A of FIG. 15.

(20) FIG. 17 is a sectional view taken along the line B-B of FIG. 15.

DESCRIPTION OF EMBODIMENTS

(21) Now, description is made of embodiments of the present invention with reference to the drawings.

(22) FIG. 2 is an illustration of a fixed type undercut-free constant velocity universal joint, which is a fixed type constant velocity universal joint of the present invention. The fixed type constant velocity universal joint comprises an outer joint member 23 having a radially inner surface 21 in which a plurality of track grooves 22 are formed, an inner joint member 26 having a radially outer surface 24 in which a plurality of track grooves 25 are formed in pairs with the track grooves 22 of the outer joint member 23, a plurality of balls 27, which are interposed between the track grooves 22 of the outer joint member 23 and the track grooves 25 of the inner joint member 26, and are configured to transmit torque therebetween, and a cage 28, which is interposed between the radially inner surface 21 of the outer joint member 23 and the radially outer surface 24 of the inner joint member 26, and is configured to retain the balls 27. A plurality of pockets 29 configured to accommodate the balls 27 are arranged along a circumferential direction of the cage 28.

(23) A deep side and an opening side of each of the track grooves 22 of the outer joint member 23 are respectively formed as a circular-arc portion 22a and a linear portion 22b. A deep side and an opening side of each of the track grooves 25 of the inner joint member 26 are respectively formed as a linear portion 25a and a circular-arc portion 25b. Note that, the outer joint member 23 comprises a cup section 23a having the radially inner surface 21 in which the track grooves 22 are formed, and comprises a shaft section (not shown) protruded from a bottom wall of the cup section 23a.

(24) A female spline portion 30 is formed in a radially inner surface of a hole portion of the inner joint member 26. That is, an end portion of a shaft 31 is fitted into a hole portion 26a of the inner joint member 26, and a male spline portion 32 formed in the end portion of the shaft is meshed with the female spline portion 30 of the inner joint member 26. Note that, a circumferential groove 33 is formed in the end portion of the shaft 31, and a stopper ring 34 is mounted into the circumferential groove 33.

(25) As illustrated in FIG. 2, a curvature center B of the track grooves 25 of the inner joint member 26 and a curvature center A of the track grooves 22 of the outer joint member 23 are axially offset in opposite directions with respect to a joint center O by equal distances F and F. In this case, the curvature center A of the track grooves 22 of the outer joint member 23 and the curvature center B of the track grooves 25 of the inner joint member 26 are axially offset to opposite sides by equal distances so that the curvature center A and the curvature center B are respectively offset to a joint opening side and a joint deep side with respect to the joint center O.

(26) Further, as illustrated in FIG. 3, six track grooves 22 of the outer joint member 23 are formed along a circumferential direction at predetermined pitches (60-degree pitches in this case). Similarly, six track grooves 25 of the inner joint member 26 are formed along the circumferential direction at predetermined pitches (60-degree pitches in this case). Accordingly, six balls 27 serving as torque transmitting members are arranged along the circumferential direction at equal pitches (60-degree pitches). In this case, it is preferred that the number of the balls 27 be equal to or smaller than ten. That is, it is preferred that the number of the track grooves 22 of the outer joint member 23 and the number of the track grooves 25 of the inner joint member 26 be equal to or smaller than ten.

(27) As illustrated in FIG. 1, an inlet chamfer (cup-inlet chamfer) 35 is formed along an entire periphery of an opening rim of the outer joint member 23, and a track chamfer 36 is formed at each boundary portion between a radially inner spherical surface portion 21a and the track groove 22. Note that, as illustrated in FIG. 7, a track-inlet chamfer 37 may be formed at each boundary portion between the track groove 22 and the cup-inlet chamfer 35. Further, although not shown, in the inner joint member 26, a track chamfer is formed at each boundary portion between a radially outer spherical surface portion 24a of the radially outer surface 24 and the track groove 25.

(28) As illustrated in FIG. 1, in an opening portion of the outer joint member of the constant velocity universal joint, at each corner portion on the opening side of the cup section, which is defined between a radially inner opening end portion of the track groove 22 and the radially inner spherical surface portion 21a, there is formed a cutout portion (cage incorporating chamfer) 40 configured to prevent the cage 28 from interfering with the outer joint member when the cage 28 is incorporated into the outer joint member. That is, the cutout portion 40 is formed on the joint opening side of the track chamfer 36. Note that, the cutout portion 40 is formed into a convex round shape, and an opening side of the cutout portion 40 is more widely cut out.

(29) Next, description is made of a method of incorporating the cage 28 into the outer joint member 23 constructed as described above. First, as illustrated in FIG. 4 to FIG. 6, the cage 28 is inserted into the radially inner surface 21 of the outer joint member 23 under a state in which the cage 28 is turned by 90 about a Y axis. Then, after the cage 28 is pushed into a bottom portion of the cup section 23a of the outer joint member 23, the cage 28 is turned by 90 about the Y axis, to thereby be arranged in a normal posture. Here, the Y axis refers to an axis orthogonal to an X axis corresponding to a center axis of the outer joint member 23.

(30) When the cage 28 is inserted into the outer joint member 23 as illustrated in FIG. 5 and FIG. 6, as illustrated in FIG. 4, under a state in which a pair of pockets 29 of the cage 28, which are arranged on 180-degree opposite sides with respect to the center axis, are fitted to the pair of radially inner spherical surface portions 21a arranged on 180-degree opposite sides with respect to the center axis of the outer joint member 23, long-side edge portions 29a and 29a of each of the pockets 29 of the cage 28 are matched with the cutout portions 40. In this manner, without interfering with the outer joint member 23, the cage 28 can be pushed into the bottom portion of the cup section 23a.

(31) Incidentally, the outer joint member 23 is made of, for example, carbon steel for machine construction. It is preferred that the carbon steel for machine construction have a carbon content of from 0.37 wt % or more to 0.61 wt % or less, more preferably a carbon content of from 0.50 wt % or more to 0.58 wt % or less. Specifically, the outer joint member 23 is made of S40C to S58C, desirably S53C to S55C specified in Japanese Industrial Standards (JIS).

(32) The track grooves 22, the inlet chamfer (cup-inlet chamfer) 35, the track chamfers 36, and the track-inlet chamfers (see FIG. 7) are formed in the outer joint member 23 by cold forging. Cold forging can be performed on the outer joint member by an existing manufacturing apparatus (such as a manufacturing apparatus described in JP 2009-185933 A).

(33) However, the track grooves 22 and the cutout portions 40 are finished by cold-forging ironing using a single ironing punch 50 as illustrated in FIG. 8, whereas the inlet chamfer (cup-inlet chamfer) 35, the track chamfers 36, and the track-inlet chamfers 37 are finished by cold forging using the existing manufacturing apparatus.

(34) That is, a forging apparatus illustrated in FIG. 8 comprises outer diameter dies 51 and 52, and the ironing punch 50, and is configured to finish, by cold forging, a pre-forged product S finished by cold forging using the existing manufacturing apparatus (member before finishing the track grooves 22 and the cutout portions 40 by cold forging). The pre-forged product S comprises a cup section 55 constructing the cup section 23a of the outer joint member 23, and a stem section 56 constructing a stem section of the outer joint member 23.

(35) Accordingly, ironing is performed using the ironing punch 50 under a state in which the cup section 55 is fitted to the outer diameter die 51 and the stem section 56 is fitted into the outer diameter die 52. As the ironing punch 50, a punch illustrated in FIG. 9 and FIG. 10 may be used. The ironing punch 50 comprises track-groove forming portions 57, radially-inner-spherical-surface-portion forming portions 58, cutout-portion forming portions 59, and connecting-portion forming portions 60 formed in a radially outer surface thereof.

(36) Incidentally, using the ironing punch 50 illustrated in FIG. 9 and FIG. 10, each cage incorporating chamfer being the cutout portion 40 is formed along substantially an entire length of the track groove 22 in a longitudinal direction of the track groove 22 as illustrated in FIG. 11A and FIG. 11B. Further, each connecting portion 61 is formed between the track groove 22 and the cage incorporating chamfer (cutout portion 40). The connecting portion 61 is formed into a round shape. Accordingly, at the time of completion of ironing forging, an interior shape of the cup section 23a of the outer joint member 23 exhibits a shape illustrated in FIG. 11A and FIG. 11B.

(37) FIG. 12A and FIG. 12B are illustrations of a shape obtained by forming the radially inner spherical surface portions 21a by turning after the shape illustrated in FIG. 11A and FIG. 11B is obtained in such a manner that the track grooves 22 and the cutout portions 40 are finished by ironing. In this case, as illustrated in FIG. 1, each of the cutout portions 40 is formed only on the opening portion side of the cup section 23a.

(38) FIG. 13A and FIG. 13B are illustrations of a shape obtained by forming the track chamfers 36 by turning after the shape illustrated in FIG. 12A and FIG. 12B is obtained in such a manner that the track grooves 22 and the cutout portions 40 are finished by ironing and then the radially inner spherical surface portions 21a are formed by turning. Also in this case, as illustrated in FIG. 1, each of the cutout portions 40 is formed only on the opening portion side of the cup section 23a.

(39) The cutout portion 40, which is configured to prevent the cage 28 from interfering with the outer joint member 23 when incorporating the cage 28, is formed at least at each corner portion on the opening side of the cup section, which is defined between the radially inner opening end portion of each of the track grooves and the radially inner spherical surface portion 21a formed between the track grooves 22. Accordingly, when incorporating the cage 28, interference between the cage 28 and the outer joint member 23 can be prevented. As a result, workability of incorporation can be increased, thereby being capable of increasing productivity.

(40) In addition, the cutout portions 40 are finished together with the track grooves 22 of the outer joint member 23 by cold-forging ironing. Thus, after the cutout portions 40 are formed, it is not necessary to finish the track grooves 22 again. Consequently, it is possible to achieve reduction of production cost and reduction of production time. The cutout portions 40 and the track grooves 22 are finished by cold-forging ironing using the single ironing punch, thereby being capable of providing uniform products (outer joint members) with high accuracy.

(41) The cutout portions 40 or the connecting portions 61 are each formed into a round shape. Thus, stress concentration on the cutout portions 40 or the connecting portions 61 can be avoided, thereby being capable of effectively preventing damage and the like.

(42) The inlet chamfer 35 of the outer joint member 23, and the track chamfers 36, the track-inlet chamfers 37, and the like of the outer joint member 23 are finished by cold forging, thereby being capable of omitting cutting work, grinding, and the like, which are performed after cold forging in the related art. Thus, a yield can be increased, thereby being capable of reducing manufacturing cost of the fixed type constant velocity universal joint.

(43) In particular, the track grooves 22 and the track-inlet chamfers 37 of the outer joint member 23 are formed by simultaneous cold-forging finishing, or the track grooves 22 and the track chamfers 36 of the outer joint member are formed by simultaneous cold-forging finishing. In this manner, productivity can be increased.

(44) It is only necessary that the number of the torque transmitting balls be equal to or smaller than ten. Thus, a degree of design freedom is high, and excellent design flexibility is attained. Further, the present invention is applicable to a variety of fixed type constant velocity universal joints.

(45) The embodiment of the present invention is described above. The present invention is not limited to the above-mentioned embodiment, but may be modified in various ways. Any one of or all of the cup-inlet chamfer 35, the track chamfers 36, and the track-inlet chamfers 37 may be omitted.

INDUSTRIAL APPLICABILITY

(46) The fixed type constant velocity universal joint according to the present invention is applicable to, for example, a front drive shaft, a rear drive shaft, and a propeller shaft of an automobile.

REFERENCE SIGNS LIST

(47) 21 radially inner surface 22 track groove 23 outer joint member 23a cup section 24 radially outer surface 25 track groove 26 inner joint member 27 ball 28 cage 29 pocket (window portion) 35 cup-inlet chamfer 36 track chamfer 37 track-inlet chamfer 40 cutout portion 60 connecting portion