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US us United States c2) Patent Application Publica oy 09) my a @y (60) TANGE et al. METHOD FOR MANUFACTURING A COIL SPRING FOR VEHICLE SUSPENSION Inventors: Akira TANGE, Yokohama-shi (JP) Hideki Okada, Yokohama-shi (JP), Isao Sumiyosbi, Yokohama-shi (GP); Mitsuhiro Swat Yokohama-shi (JP) Assignee: NHK SPRING CO, LID.. Yokohama-shi (JP) Appl.Nos 13/207,046 Pied: Aug. 10,2011 Related US. Application Data Division of application No, 12/732.480, filed on Mar 26, 2010. which is continsation of application No, PCT/IP20101052659, filed on Feb, 22, 2010, ion 1200550. 20 AL ao) Pub. No.: US 2012/0055023 Al (43) Pub, Date Mar. 8, 2012 G0) Foreign Application Priority Data Jun. 17,2009 GP) 2009-144460 Publication Classiticat GI) neck. BRIE 35/00 2005.01), (32) US.CL 29789691 on ABSTRACT A spring wire with hardness of 50 to S6HRC is subjected to first and second shot pening processes within a warm work ing femperature ninge of 150 t0 350° C. In the fist shot peening process, fist shot ofa shot sizeof atleast 1.0 mm Js used. In the second shot peening process, a second shot smaller in shot size than the fist shots sued, Through these shot peening processes, compressive residual stress. is imparted to the spring wire, The spring wire includes residual stress increase part, residual stress penk part, and residual stress decrease part. In theresa stress decrease part part including a compressive residual stress magnitude ‘equivalent to the magnitude the compressive residual siress ata surface of the spring Wire exists a a region ata depth ‘exceeding the permissible pit depth Patent Application Publication Mar. 8, 2012 Sheet 1 of 7 US 2012/0055023 AI 10 FIG.1 FIG.2 Patent Application Publication STAI (hot-formed coil spring) Heating of material Hot coiling Quenching Tempering Hot setting First shot peening (warm peening) Second shot peening (warm peening) Presetting Painting Inspection FIG.3 Mar. 8, 2012 Sheet 2 of 7 US 2012/0055023 AI Patent Application Publication Mar. 8, 2012 Sheet 3 of 7 US 2012/0055023 AI START. (cold-formed coil spring) Quenching of material Tempering Cold coiling Stress relief annealing Hot setting First shot peenine (warm peening) Second shot peening (warm peening) Patent Application Publication Mar. 8, 2012 Sheet 4 of 7 US 2012/0055023 AI 13 Example 1 2 } 3 bg é Residual stress value (MPa) 5 0 04 02 03 04 05 Depth from surface (mm) FIG.S5 — 6 8 8 Residual stress value (MPa) 0 o4 02 03 04 (OS Depth rom surface (mm) Patent Application Publication Mar. 8, 2012 Sheet 5 of 7 US 2012/0055023 AI p [Example 3| ample 7 12 1000+ 5, € 800 = B -600 3 400 q & -200 0 + 0 04 02 03 04 05 Depth from surface (mm) FIGS, : Comparative 1000 T3 example t & -800 = -600 3 400 & -200 0 ot 02 03 04 05 Depth from surface (rm) Patent Application Publication Mar. 8, 2012 Sheet 6 of 7 US 2012/0055023 AI (Example 1 (S822) ZZ" Spring steel S | Example 2 (1200MPa) shot size 145% 53.5HRC ( ce Comparative example 1 100% shot size, SEE) aaa ae ae Te Totowa Tv wo Corrosion life (9%) FIG.9 Example 4 ( Shot size 1.040.67 ‘SAE 9254 Example 5 7 (1eoonPa) ($ret ses ZZZLLLLLLLA 160% 53.5HRC i Comparative 65% (corrosion fe of case of hot eze 1100 MPa is defined as 100%) (Sehr) aria aa io dose orion Corrosion lite (9) FIG. 10 Patent Application Publication Mar. 8, 2012 Sheet 7 of 7 US 2012/0055023 AI FIG. 12 US 2012/0055023 AI METHOD FOR MANUFACTURING A COIL, ‘SPRING FOR VEHICLE SUSPENSION (CROSS-REPERENCE TO RELATED "APPLICATIONS, 10001} This application isa Divisional Application of US. pplication Ser. No. 12732.450, fled Mar. 26, 2010, whic application is based upon and elaims the Benet of priority liom prior Japanese Pateat Application No, 2009-14460, filed Jun, 17, 2009, the entire contents of both of which are Jncomporated herein by reference. BACKGROUND OF THE INVENTION 0002] 1. Field ofthe Invention [0003] The present invention relates to a coil spring for Yehicle suspension used for a suspension mechanism of & vehicle such as an automobile othe like, excellent in coero- sion durability, and method for manufacturing the same. [0008] 2, Description of the Retated An [0005] _Itisknown that coll spring fr suspension mecha- nism issubjecttoan influence of an antieeze agent scattered ‘on aro in the wintertime or the like. The antifreeze agent ‘contains salt, and hence the agent promotes corrosion ofthe surface of the coil spring constituted of spring steel. It is (tch pit) particularly exerts great influence upon the durability of the col spring. For example, 8 shown in FIG. 11, part ofthe surface la of the spring wire 's comoded to form a hole-like shape by moisture or salt, soherehy a corrosion pit 2s formed. Although the shape ofthe ‘corosion pit2 varies, there is even a corrosion pit 2 having 3 ‘ross section as schematically shown in, Jar example, FIG, As shown in FIG. 13, when the coreosion pit 2 jin level or more, and the weight of the vehicle is continvously applied t he col spring, fatigue ‘rack 3 vectra the bottom part 2a oF the like ofthe pit 2 When the rack 3 grows lat, the eol spring is broken. In colher words, even when the col sping is used ina eorosive ‘eovironment, the col spring ean be used without breakage if the sizeof the corrosion pil within the permissible pit depth Ron 10007} On the other hand, itis desired that the col spring Jor suspension be used at higher stress in order (0 effect ‘weight redoction of a vehicle. In order to realize the higher ‘ress in the coil sping, i becomes important to impart com- pressive residual stress tothe vieinity ofthe surface of the spring wire. It is known from the past that by subjecting coil spring to shot peening, compressive residual stress is Jmparted tothe vicinity of the surface ofthe col spring, and the durability thereof is enhanced, For example, in Jpa. Pat. Appa. KOKAL Publication No, 2000-345288 of Jpn, Pat. Appl. KOKAI Publication No. 2008-106365, mulistage sot pening is disclosed, Inthe multistage shot peening shot pecning is curred outa plurality of mes in dividing man- [0008] As means for producing compressive residual sress ‘na mepion from the surface ofthe spring (oa deep position, stress pening and warm peening (hot peening) are known In the stress peening, the shot is applied to the coil spring in-2 state where the spring is compressed. In the warm peening, the shots applied tothe col spring ina state where the spring js heated ata temperature of abowt 250°C. In comparison ith the ordinary shot peening 1 be carried out at room Mar. 8, 2012 femperature, in the stress pening or warm peening, itis posible to cause compressive residual sres fo appear in @ ‘gion up to a deep position in the material, However, the rest peening requires equipments configured to compress ‘the coil spring. Furheemore, in the stress peening, the shot is ‘applied to the eoil spring in a state where the coil spring is compressed, and hence gaps between spring wire parts ‘become small. Accordingly, there isa problem that itis hard forthe shot to hit the insde of the coil spring oF positions between the spring wire parts. 0009} In a conventional coil spring for suspension, large ‘compressive residual sre is imparted tothe Veinity’ of the surface ofthe spring by shot peening. However, when the coil Spring for suspension is used in a corosive environment ia ‘which a eomosion pit occurs, the col spring breaks in some cases after a relatively short peviod of use by the growth ofthe cortosion pit. Thus, its also proposed to improve the eorro- sion resistance, and suppress occurrence ofthe corrosion pit and growth ofthe corosion pit by coneving the components of the material Spring ste!) [0010] For example, the corrosion resistance of the coil Spring is improved by adding an alloy element such as Ni Ce, ‘Mo or the like tothe spring steel. However, the spring steel containing such an alloy element is expensive, this being a ‘use making the cost of the col spring high. Further. once the size ofthe eorosion pit eches the permissible pt dep, there is the possibilty ofthe coil spring being broken while making fatigue erack occurring a a bowom part or the Tike of the corrosion pita stating point BRIEF SUMMARY OF THE INVENTION [0011] Anobjectofthe present invention isto provide coil spring, fr vehicle suspension capable of enhancing the cot rosion durability, and being used at higher stress, and method ‘or manufacturing the same. [0012] coil spring Tor vehicle suspension ofthe present invention i that mad ofa spring wire to which compressive residual sires is imparted by shot poening and comprises residual stress increase par, residial stress peak part, and residual stress decrease part. Inthe residual stress increase part, the compressive rsidal stress increases from the st lage ofthe spring wire in a depth direetoa, in the residual stress peak part the compressive residual sress becomes the ‘maximum, Inthe residual steess decrease pat, the compees- sive residual stress decreases from the residual stress poak part in the depth direction ofthe spring wie. Furthenmore, in fhe coil spring in the residual stress decrease part, 0 part comprising the compressive residual stess magnitude of ‘which is equivalent to the magnitude of the compressive residual stress at the surface of the spring Wire exists st 9 positon at a depth exceeding the peaisible pt depth ofthe spring wire [0013] According to the col spring for vehicle suspension ‘ofthe present invention, even when the eonasion pit grows to 8 position near the permissible pit depth, itis possible to prevent a fatigue crack from occurring a the bottom part oF the lke ofthe corrosion pit, and enhance the eormsion dur bility. As a result of this, it becomes possible to use d suspension col spring for vehicle suspension at higher sre ‘and effect Weight reduction ofthe vehicle, [014] - When the permissible pit depth ofthe cil spring is (0.25 mm, itis desirable that compressive residual stress of 400 MPa or more (implying an absolute valucof 400 MPa or nore, the sume is tre of the following) be imparted 10 2 US 2012/0055023 AI ‘ston fom the srfce othe spring wire positon atte permissible pit depth. As the handnes ofthe spring wie the fares of 501056 [IRC i recommendable. Further, it is desiable that a position which is located deeper than the restdualstres poke put and at whic the compressive tesa srss gins fo laglyfower be oat dacer than (02 mm from the srface ofthe spring. Forte, ii also dlesrabl that compressive reside! sress cf 400 MPa or mor bo impart reaion from the srace to a position at sraepih of 03 mm [0015] A method for manufacturing a coil spring for ‘hick snpenson ofthe preset invention comprises bond proces in sot peeing proces nl second shot pen ing process. ne bending proces a sring Witeconstuted ‘lain sels ormed into alc shape Inthe fist shot pesning proces, compressive residal ses i imparted 0 thespring wie by aplsing the pring wire with heli sho ‘fast sis of LO mm or more. The second shot poor proces is cad ou ater te fst sho peering proces. In the acs sbnt peeing proces the spring wn applic tithe soon slr inahtsiz than the fist ho. By the fit shot peering process, an second shot pening prO- ‘es, res tess increas part resi es Pea Pet and resales decrease pase produced inthe pring vir and inthe esl stress drove prt, par comprise ing ihe somprssiveresoal siress mognitade of whichis ‘valent themegntieof he compressive resis sess the surlaceo the sping wire penta ata postion at ‘depth exceeding the permissible pit depth of the spring wire. [0016] According 10 the manufacturing method of the preset vention, iis posible to ese a high level of sme Prose eid se elective in preventing occurence of {ign cack ant development ofthe cack to appear in region from the sure ofthe srg wire To a poston at & ‘pth exceeding he permite pit dep Putrmore iis rersible to make a difference berween the compressive Fesidoal tes nen the surface ofthe sping wie and come pressive esidal stress near he baton prt ofthe cotoscn Pita Ass rom ofthis, ts posible oobi somes five resihal sess cstibution highly fictive preventing 2 tig ck fom occurring in the corrosion pit [0017] Inthe present invention, iis recommendable 19 ay ot heist shot poeing process ad second sho pe ing procas in asl whee to spring wire is Kept at processing temperature of 150 to 350" C. The processing tempers inthe fir sot peeing process higher an the processing temperature in tho second shot pening process Fer itis dvisabl to make the Kinetic energy ofthe ist shot ger han the kine energy’ ofthe soon st [0018] Additional objects and advantages of the invention Wil be set forth inthe description which flows in part Sill be obvious from the dexerton, or may be feared by practice ofthe iavention The objects and advantages of te invention nay be realized and obtsined by means of the instruments aod combinations psticulany pointed out force, BRIFP DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING 10019] The accompanying drawings, which are ineorpo- Fated in and consitte a part of the specification, illustrate ubodiments of the invention, and together with the general Mar. 8, 2012 description given above and the detailed description of the embodiments given below, serve to explain the principles of the invention [0020] FIG. 1 is aside view of part of an automobile pro= vided with a coil spring for suspension according (0 an embodiment of the present invention; [0021] FIG. 2 is a perspective view ofa coil spring for suspension shown in FIG. 1; 0022] FIG. 3 isa fowchan showing an example of manu- Tacturing processes ofthe col spring for suspension shown ia FIG.2; [0023] FIG. 4 is a lowehart showing another example of | manufacturing processes of the coil spring for suspension shown ia FIG. 2; [0024] _ FIG. Sis graph showing the compressive resus! swst distribution of example 1 according to the present [0025] _ FIG. 6s graph showing the compressive residual stress distribution of example 2 aecording to the prese [0026] FIG. 7s graph showing the compressive residual sess distribution of example 3 acconting to the present 0027} FIG. 8s graph showing the compressive residual stress distribution of comparative example Is [0028] FIG. 9s graph showing the corrosion life ofeach ‘of examples 1 and 2 according to the present invention, and ‘comparative example I: [0029] FIG. 10isapraph showing the corrosion life ofeach fof examples 4 and 5 according to the present invention, and ‘comparative example 2: [0030] FIG. 11 is cross-sectional view schematically showing an example of a cormosion [0031] FIG. 12 is 2 cross-sectional view schems showing another example ofa corrosion pity and [0032] FIG, 13 is » cross-sectional view schematically showing @cofrosion pt in which crack fas cecurred, aly DETAILED DESCRIPTION OF THE INVENTION [0033] A coil spring for vehicle suspension according to an ‘embodiment of the present invention, and method for mann tactring the col spring will be described below with refer ence tothe drawings. {0034} _ suspension mechanism 11 of a vehicle 10 shown in FIG. 1s provided with el spring 12 for viele suspen- sion (hereinafter refered to simply as @eol spring 12), and shock absorber 13. In the col spring 12 shown in FIG. 2,0 ‘pring wire 20 is formed into’a helical shape. The coil spring 12 elastically supports the load ofthe vehicle 10 in a state ‘where te spring 12 is compressed inthe direction of the axis x. [0035] An example of the coil spring 12 isa eylindical coil spring. An example of wire diameter (show in FIG.2) oF the spring wire 20s 125 mm, Anaverage col diameter Dis 110.0 mm, fre length (length at no oad) is $82 mam, number of active tums is 5.39, and spring constant is 33.3 Nim. ‘though the main stream of the wire diameter of the col spring 12 is § to 21 mam, diameters other than the above may also he employed. Further, cil springs of various forms sch as a baerel-shaped spring, double headed conical spring, US 2012/0055023 AI variable pitch coil spring load axis the lke may also be employed. tapered col spin trol col spring. a Example 1 10036] |The ype of steel ofthe spring wire 20 is high eor- rosin resistant spring ste! (n this description, referred to as spring stcl Stor convenience). The spring steel Sis ofa steel typeenhncedin corrosion resistance, and the chemical com- ponents (mass 6) thereof are C: 0.41, Si: 1.73, Mn: 0.17, Ni 0.53, Ce 1.08, 0.163, Ti: 0.056, Cu: 0-21, and Fe: remnant 10037] FIG. 3 shows manufacturing processes of a hot ormed coil spring. In a heating process SI, spring wire ‘which isa material forthe eol spring is heated at an austen iting temperature (higher than A; transformation point, and Tower than 1150°C.). The heated spring wire is bent into-a helical shape in a bending process (coiling process) S2. Thereafter, the coiled spring wire is subjected fo heat teat ‘meat suc asa quenching process S3, tempering process S4 ‘andthe like, 10038] The spring wire is ermal refined by the heat treat- ‘ment so that the hardness of 50 o 56 HIRC can be obtained. For example, a col spring of design maxieuim stress of 1300 MPa is thermal refined so that harness of $4.5 HIRC can be ‘obtained. A coil spring of design maximum stress of 1200 MPa i thermal refined so that hardness of 53.5 HIRC can be ‘obtained, Further, ina hot setting process SS, a lod in the axial direction ofthe coll spring is applied to the col spring Tora predetermined time. The hot setting process SS is carried ‘outas warm working by utilizing the remaining hea after the heat iratmeat. 10029] Thereafter, fist shot peening process Sis carried ‘out. Inthe fist shot peening process S6, the first shot (cut ee pieces made of iron) having a shot size (grain size) of 1.0mm 's used, The spring wire is applied withthe first shot at a processing temperature of 230" C, ata velocity 0176.7 mis, ‘and with Kinetic energy of 12.1 b10™ J. As a result of this, ‘compressive residual tress appears in awide region from the furfice of the spring wie in the depth direeGon, The com- pressive residual stress distribution wll be deseribed later in ‘etal. Ics desirable hat the surface roughness ofthe spring ‘ire obtained by the fist shot poesing process S6be 75 ym oF Jess It'should be noted that the velocity ofthe shot value ‘obisined by multiplying thecircumferental velocity obtained fom the diameter of the impeller of the shot peening machine, and rotational speed ofthe impeller by 1.3. For ‘example, when the diameter of the impellee is 490 mim, and rotational speed ofthe impeller is 2300 rpm, the velocity of the shot bacomes 1330-4933, 14230060-76.7 mis [0040] _Aterthe first shot peening process S6is carried out, asecond shot peening process S7 scarred out. ln the second shot peening process S7, the sevond shot smaller in size than the fist shot i used. The shot sizeof the second shot is 0.67 ‘mm. The spring wire is applied withthe second shot at & processing temperatureof 200 C.,ata velocity of 46am, and ‘with kinetic energy of 1.31%10™ 3. [0041] In the second shot pecaing process 87, the second shot smaller in size than that of the first sh in the first shot peeing S6 is used. Furthermore, the velocity’ ofthe second Shot in the second shot posning process S7 is smaller han the ‘velocity ofthe fist shot in the first shot peening process S6. Asa result of this, the large surface roughness of the spring wire after the first shot peening process $6 can bemadestall by the second shot poening process S7, and the surface state ‘of the spring wire is improved. It should be noted that as Mar. 8, 2012 another example ofthe second shot peening process S7, the Spring wire may be applied with the second shot having.a Shot size of 0.40 mu ata processing temperature of 200” Cat a velocity oF 86.7 mis, and with kinetic energy of 0.99x10" J [0042] Table! shows datain which Kintic energy valuesof the shots are compared with each other in teams of shot peening conditions. When the shot size is larger the kintic energy becomes larer even ithe same velocity is employed For example, when the large-rain shot having a shot size of 1 mum is used, the kinetic energy bevomes about 1.5 times that of the shot having a shot size of 0.87 mm, When the large- arain shot having a shot size of 1.1 mm i used, the kinetic fener hecomes abou twice that ofthe shot faving the shot ‘ize of 0.87 mm, Conversely, when the small-grain shot hav= nga shot size of 0.67 mm is sed, the kinetic energy becomes Jessthan half that of the shot having the sot size of 0.87 mm. ‘When the shot having ashot size of 04 mms used, the kinet energy becomes less than that of the shot having the shot size (00.67 mm even ithe velocity is made about twice. [0043] In each of al the cases including example 1, and ‘examples 05 tobe described later, the kinetic energy of the fist shot ofthe first shot peening process Sé is made greater ‘han the kinetic energy ofthe second shot ofthe second shot peening process 7. [0044] As the processing temperature in each of the fist shot peening process S6 and second shot peeing process S7, a temperature within a range of 150 to 350" C. is suitable That is, these processes are warm pening (hot peening) pro- cesses utilizing the remaining heat after the heat treatment. Funliermore, the second shot peening process $7 is carried ‘out ata processing temperature lower than the ist shot pee- ing process 86. [0045] According to the shot peening processes S6 and ST fof example 1, itis possible to produce large compressive residual stress fom the surface othe deep posi ‘compressing the cil spring unlike inthe conventional sess peening. AS a result of this, equipmeats coatigu press the col spring are made unnecessary unlike i of stress peening. Furthermore, intervals between the spring ‘wire pars are not nacrowed unlike inthe stress peening, and Ihence its posible for the shot to suliciently hit the inside oF the col spring or positions between spring wire pars. [0046] After the to stapes of the shot peening processes ‘6nd S7 have been caried out, a presetting process SB and pinting process S9 are carried out. Thereafter, inorder to nspoct the extemal appearance and characteristics ofthe coil spring, an inspection process SI0 is conducted. I should be ‘noted thatthe presetting process SB may be omitted. [0047] FIG. 4 shows a manufacturing process of a case ‘where the coil spring is eoiled inthe cold working. As show in FIG. 4, the spring wire before being subjected to the coiling racess is subjected in advance wo eat treatment such a8 @ {quenching process SH, tempering process $12, andthe lke, ‘The spring wire is formed into & helical shape in a bending process (coiling process) $13 to be carried out as cold wor ‘ing, Theteafer, ina stess relief annealing peocess S14, the coil spring i left as itis inan atmosphere ofa predetermined ‘emperanire for a predetermined time, whereby'the process- ing strain caused during the formation time is eliminated. [0048] Thereafter, in this manutieturing process shown in FIG. asin the ease ofthe hotformed coil spring of FIG. 3, the hot setting process $5, fist shot peesing process 6 second shot peening process S7, presetting process S8 pai ing process $9, and inspection process S10 are caried out. It US 2012/0055023 AI shouldbe note tat the col spi ‘warm working I should he no $8 may be omited 0049] FIG. 5 shows the compressive residual stress dist buon ofthe col spring of example I, The abscissa of FIG. § represents postions from the sraceo he spring wire in the ‘pth diseetion, Although the ordinate of FIG. 8 represents the residual sess, in acordance with the customs of the tecnica ld, the compressive residual stress Valves ate ‘expressed 38 nogative vals. 10030] "As shows in FG. 8, ths compressive residual stress ofthe cil sping of example 1 incades a residual stress Sincrease put TI high stress pur residual ses peak pat 13, and residual sites dctese pat 14 nthe residual sess inreuse part TH, the compressive resi stress increases from the surface of tho sping wie toward the inside of the Spring wie inthe depth ircetin. In the high swess prt 72 the compressive residual sess is mntaned thigh evel Jn the residual stress peak part T3, the compressive residual stress hevomes the maximum ln the residues decrease prt, the compressive residual sess decreses from the residual stress peak part 13 inthe deplh direction ofthe spring ‘wire. Furthermore, nthe cil ping of Ui example nthe residual strss decrease part T4, pat B having the eompres- Sive residual sires magnitude of which is equivalent (0 the "nied ofthe compressive rescalstrese value A atthe furface of the spring wie exists at position at a depth ‘xceoding the pemnssible pit depth. ofthe spring wie {001} Here, the permissible pit depth Ry implies the raximom pit depth associated withthe possibility ofthe coil Spring for suspension having the eompressive residual sess Alstbution obtained by the conventional shot pening being broken while making a ftigue crack occuring at a bottom part or the like ofthe eorosion pit staring point. Inthe ‘onveaionl coil spring, wen the coeosion pit depth ets ‘lose (0.240 0.25 mim, the coil spring is broken ith hgh probably. The pemisible pit depthinthiscas is 0.25 mm {0082} _As shown in FG. 5, inthe coil spring of example 1, the par B having the compressive residual tess mognitde ‘of which is euialent othe magnitude of the compressive resists value. atthe surfs ofthe sping wire exists fata position ata depth excesding the permissible pit depth Roy, of the spring wie. Furhemore, the coll sping of ‘example I has compressive residual stess of ~400 MPa or ‘ore ia wide region fromthe surface toa positon at depth ‘exceeding the pemissible pit depth Ry 10083] In cach ofall the cases inching example 1, and ‘examples 210 to he described ltr, two-stage shot pooning {rtm donble sot pecning) consti of the ist bot poe ing process Sand Second shot peening process STi carried ‘ou That i, by the Ht sot posing process 86 ofthe fist stage, te peak ofthe compressive resid sess eppears ata Position deep from te surface and, moreover the compres- Sive residual sess oecurs upto the dep position. Furth, by the second shot poening ravens S7 of the second slog, is possible to enhance the compressive residual ses nar the frface as indicated bythe aro hin FIGS ln this way its pensible to obtain the high ses prt T2in which the come Presiveresidusressis msintsinedat a ighlevelinaresion From the vicinity ofthe surface wa dep psitin. {00S4) Ie should be noted that when the spring wire is Ictein the atmosphere the surface threo isdecarbonized, andthe hardness of the nrface is made lowcethan the inside by about 125 IV. The stenuth ofthe compressive residual may also be coiled in the that the presetting process Mar. 8, 2012 stress is proportional to the spring hardness, That is, as the spring hardness becomes smaller the compressive residual ‘rest also becomes smaller When the sping hardness is 51S TH which is the loner limit ofthe hardness rage of $010 56 HRC (615 to 615 HV), and the minimum hardness of the surface ut which decarbonization has besa caused is 390 HV, the compressive residual stress value ofthe sure at that time is tat about 400 MPa or more. Example 2 [0088] ‘The type of steel of the spring wire is the high corrosion resistant spring see (Spring steel S) identical with example 1. The manufacturing processes are identical with example I except for the size ofthe shot used in frst shot peening process S6. In this example 2, the ist shot of «shot size of 1.1 mm was use in te fist shot peening process S6. After the first shot peenng process S6, a second shot pening process $7 was eared ont by using the second shot having a Shot sizeof 0.67 mm, The velocity ofthe shot and processing temperature were identical with example 1 [0086] _ FIG. 6 shows the compressive residual stress distri- ‘ution of example 2. The eoil spring af example 2 also has, like that oF example 1, a residual stress inerease port high stress part'T2, esiual stress peak part T3, and residual tress decrease part T4, As described previously, inthe residual Stress increase part TH, the compressive residual siess increases from the surfe of the spring wiee in the depth rection, In the high tess part T2 the eompecssive residual sires is maintained at high level. the residual stress peak part T3, the compressive residual stress becomes the iax- ‘mum, Inthe residual stress decrease part T, the compressive ‘esihal stress decreases fom the resid stress peak par 3 ‘nthe depth direction of the spring wre In the col spring of example 2, ay inthe case of example 1, apart B having the compresive residual stress magnitude of which s equivalent tothe magnitude of the compressive residual ses value at te surface of the spring wire exists at postion ata depth exceeding the permissible pit depth, of the spring Wie Furthermore the coi spring of example 2 has compressive residual stessof 400 MPa or more ina wide region fromthe surface to position ata depth exceeding the permissible pit Aepth Rae Example 3 [0057] The type of steet of the spring wire is the high corrosion resistant spring see pring stel 8) dential with example 1, The manufacturing processes are identical with ‘example 2 except that high-frequency heating is used for heat ‘eeatmentofthe spring wire Inthisexample3, the spring wire is heated by high-irequency heating in a quenching process 3, whereby the surface of the spring wice i prevented from being decarbonized. Ina first shot peening process S6, the fist shot having # shot sizeof 1.1 mim was used, Ina second shot peening process S7. the second shot having. shot sizeof 0.67 mm was used. The velocity ofthe shot and processing temperature were identical with example 1 [0058] FIG. 7 shows the compressive residual stress disti- bution of example 3. The coil spring of example 3 also has, Tike those of examples | and 2, a residual stress increase part ‘TH, high stoss part T2, residual stross peak part T3, and residual sess decrease part T4. Further. in the residual stress decrease part T4, 9 part It having the compressive residval sess magnitude of whieh is equivalent to the magnitude of US 2012/0055023 AI the compressive residual stress value A atthe surface of the spring wire exists at @ position at a depth exceeding the permissible pit depth R,q. of the spring Wire. Furthemore, the coil spring of example’ as compressive residual stress of 400 MPa or more ina wide region from the surface to @ positon at a depth exceeding the penmisible pit depth, Example 4 10059] The steel ype of SAF 9254 was used asthe spring Wire. The chemical components (mass %) of SAE 9284.eC: 051 10 0.59, Si: 1.20 t0 1.60, Mn: 0.60 10 0.80, Cr: 0.60 10 (0380, $: 0.040 max. P: 0.030 max., and Fe: remnant. The manvfacturing processes are identical with example I. lnthis ‘example 4, the spring wire constituted of SAF 9254 (hand ness: 53.5 HRC) was subjected oa first shot peening process (elocity: 76 ms, processing temperature: 230°C.) by using the first shot having a shot size of 1.0 mm. Thereater, the spring wire was subjected to a second shot peening process (locity: 46 mis, processing temperature: 200° C.) by using the second shot having a shot size of 0.67 ma Example 5 [0060] The stec ype of SAF. 9254 was used asthe spring Wie, and coil spring was maaufactured by the same pro- ‘esses as example 2. That is, in example 5, the spring wire ‘constituted of SAB 9254 hardness 53.5TIRC) was subjected to-a first shot pening process (velocity: 76 m/s, processing temperature: 230°C. )by using te frst shot having ashot size ‘of 11 mm. Thereafter, the spring wire was subjected to 2 second shot peening process (velocity: 46 mis, processing temperature: 200° C.) by using the second shot having a shot size of 0.67 mum, Comparative Example 1 10061] As the spring wire, the high corosion resistant spring steel (spring steel S) identical with example | was tsed, The mantificturing processes are common to example 1 ‘except for the shot peening conditions. In comparative ‘example fina rt shot peening proces, thespring Wire Was ‘applied with the frst shot having shot size oF .87 mm at 9 velocity of 76 mis. The processing temperature was 230? C. Thereafter, in second shot peenng proces, the spring wire was applied with the second shot having a shot sizeof 0.67 rm ata velocity of 46 mis. The processing temperature was 200 €. {0062} FIG. 8 shows the compressive residual stress distri- bution of comparative example 1. As showa in FIG. 8, the ‘maximum value ofthe compressive rescal stress of com parative example I Bears comparison with examples I 0 3 However, in comparative example 1, a part BY at which the ‘compressive residual stress equivaleat to the compressive residual stress value A’at the surface ofthe spring wire exists Js located at a position considerably shallower than the per- missible pit depth Ryq, (0.25 num). As a result of this, there was the possibility of fatigue erack occurring ata botiom part or the like of s corrosion pit and the eol spring being broken when the corrosion pit grew close tothe permissible Pit depth (0.25 mm). (Comparative Exaaple 2 [0063] | Comparative example 2 is identical with compara- tive example I except that SAE 9254 was employed as the steel type forthe spring wire, In comparative example 2, the Mar. 8, 2012 spring wire (hardness: $3.5 HRC) constituted of SAF 9254 ‘was subjected to first shot pcning process (velocity: 76s, processing temperature: 230° C.) by using the frst shot hav- Jing a shot size of O87 mum, Thereafter, the spring wire was subjected toa second shot pening process (velocity: 46 mis, processing temperture: 200° C.) by using the second shot having a shot size of 0.67 mm, Fatigue Test Result [0064] FIG. 9 shows results of corrosion fatigue tests of | ‘examples | and 2. and compamitive example I In the coero- sion fatigue test, the coil spring was subjected to test eycles cach of which i constituted of subjecting the coil spring to spraying of salt water (5% NaCI) for 30 minutes, thereafter subjecting the col spring to vibration 3000 times, and then ‘Keeping the col spring in an environment having huasdity of 98% for 23 hours until the col spring is brokea, and the total ‘numberof vibration was measured, The test tress was 1200 MPs. [0065] _As shown in FIG. 9, in example 1, the corrosion life was markedly improved to 123% ia comparison with the corrosion life (100%) of comparative example I. Further ‘mony, in example 2, the corosion life was largely improved further to 145%. As described above, in the col springs ofthe shove examples I and 2, the corrosion durability ofthe sus- pension col springs was largely improved by the warm peen- ng using the lage-grin shot having a shot sizeof LOmum oF [0066] In the conventional suspension spring, when the ‘cortosion pit grows to approach the permissible pit depth yaw erack occurs earlier ata bottom part of the pit and the crack grows rapidly, thereby breaking the spring. Converscly, inthe examples described above, compressive residual stress ‘exceeding ~400 MPa is imparted even to a deep position ‘exceeding the permissible pit depth R,.. Furthermore inthe ccxamples described above, the compressive residual stress valuesata postion exceeding the permissible pit depth Ry is ‘equivalent to or greater than the compressive residual sress value atthe spring surface, and iti possible to preveat the sradieat of change in the compressive residual stress from becoming steep. Asa result of tis, in each ofthe oil springs ofthe examples aeconlingto the present invention, even when the corrosion pit grows to reach the pemissible pit depth Rar the compressive residual stress still remains at the «dep, and hence itis possible to suppress the occurrence of a ‘rick rom the bottoms part of the pt. Accordingly, even wha a crack has occurred, itis posible to slow the subsequent growth of the crack, whereby its possible to tremendously improve the eorosion durability [0067] FIG. 10 shows resus of corrosion fatigue tests of | ‘examples 4 and 5, and comparative example 2. Here, the ‘ortosion life of «ease where the corrsion fatigue test ofthe col sping of comparative example 2 is carried out atthe test stress of 1100 MPa is defined as 100%, and corrosion lives of ‘ses where tess are carried out at the test stress of 1200 MPa by increasing the lest stress by 100 MPa are compared with the corrosion life of above comparative example 2. When the stress was increased fom 1100 to 1200 MPa, the eorrasion Tife was lowered 10 65% in eomparative example 2. Con- versoy, in example 4, the comsion life of 104% which was snore than the conveational ane was obtained, Furthermore, in example 5, the corrosion life was largely impmved to 160%, US 2012/0055023 AI 10068] As described above, inthe coil springs oF examples and 5, even wien the employed stress was increased by 100 MP, it was posible wo make the corrosion durability equiva- leat to orhigher tan the conventional col spring. As a result ‘ofthis, it became possible to use the suspension coil spring at higher stress, and eect weight reduction, For example, in the ‘conventional spring ofthe 1100 MPaclass, the wire diameter ‘0812.1 mum otal numberof turns was 5.39, and weight was 2.09 kg, wheress in the spring o be used at 1200 MPs, the Wire diameters 11.7 mm, total number of tums is 4.98, and weight is 1.79 kg, whereby weight reduction of 14.4% is ‘achieved, Inthe spring to be used at 1300 MPa, the sce diameters 114mm, total number oftumsis4.61,and weight, js 1.58 kg, whereby weight reduction of 23.4% is achieved, 10069] In the compressive residual stress distribution that ‘can be acquire by the conventional shot peening, even when, itis attempted to procice compressive residual stress greater than ~400 MPa up toa depth of about 0.25 mm, attenuation _anidient ofthe compressive rescal stress from the srface in the depth ditection is steep, and hence the compressive residual sires at the surface must he made extremely high. As ‘aresulto his, itas been dffculto realize the above attempt ‘dueto the limit in the manufacturing method. Pure, ite not impossible to produce compressive residual stress up to @ _desp region by using the eonventional shot size and by mak- ing the velocity higher. However, in thisease, inorder to make the kinetic energy ofthe shot twice, its necessary to inerease the velocity from 78 mvs (impeller rotational speed 2300 rpm) to 109 m/s (impeller rotational speed 3279 rpm). Asa resultof this, problems of an increase in Boise or vibration, increase in power consumption, increase in wear of the equipment, and the like are caused. Furthermore, in view ofthe msanitur- ing cost, increasing the velocity of the shot is not suitable for ‘mass production (practical application). Further, in the con- ventional shot poeaing, the magnitnde of the compressive residual stress at the bottom par of the corrosion pits matk= ‘edly and relatively lower than the magnitude ofthe compres sive residual stess at the surface. As a result of this, even when the compressive residual stress i produced up to positon nthe viinity ofthe bottom part of the corrosion pit this ha litle effet on preventing a crack from occuring ia the vicinity ofthe bottom part ofthe corrosion pit. 10070] | Conversely inthe compressive residual steess dis- tribution of each of the examples according to the present invention, lage compressive residual stress (greater than 100 MPa) is imparted toa deep portion exeeeding the bot- ‘om part ofthe corrosion pit. Furthermore, the compressive residual stress near te surface ofthe spring. and compressive residual stress near the bottom part of the corrosion pit are ‘maintained at the same level. Moreover, the gradient of a ‘change in the compressive residual stress is prevented rom becoming steep in the region from the spring surface to the bottom part of the corrosion pit By virtue othe above fies, ‘even when the corrosion pit grows, it ispossbleo effectively prevent crack from occurring near the bottom part ofthe pit ‘or prevent the crack fom growing. [0071] Regarding the effect of each of the examples ‘described above, the same tendency is in evidence irespec~ tively ofthe stel types, in many’ steel types including the above-mentioned high corrosion resistant spring steel (spring steel S), SAE 9254 andi, for example the spring steel SUP7 ‘conforming to Japanese Industrial Standards (JIS), the same result was obtained. Furthermore, according to the present Mar. 8, 2012 invention, its possiblete enhance the corosion durability by 38 an ordinarily used spring steel for a suspension coil ing and hence anetfect of making it possibleto prevent the ‘terial cost ofthe eo spring from Mecoming high is aso ‘obtained. It is possible to apply the coil spring according to the present invention to suspension mechanisms of various vehicles including automobiles, [0072] Additional advantages and modifications will ‘wadlly occur to those skied inthe at, Therefore te inven- ‘ion in is broader aspocts isnot limited tothe specific details ‘and representative embodiments shown ad desribed herein. Accordingly, various modifications may be made without ‘Sepang from the sprit or scape of the general inventive tencept as defined by the appended claims and their equiva- eats. ‘What is claimed is: 1. A method for manufacturing a ev spring for vehicle suspension, compeising: performing a bending process of forming a spring wire ‘comprising a spring steel into helical shape: performing a first shot peening process configured 10 impart compressive resial sires to the spring wire by applying the spring wirea first shot ofa shot sizeof at least 10mm: and performing a second shot peening process configured (0 ‘apply tothe spring wire a second shot that smaller in shot size than the fist shot, after performing the fistshot peening process: ‘wherein, by performing the frst shot peening process and the second shot peening process, there are generated in ‘thespring wire().a residual stress inerease partin which fan absolute valve of the compressive rescal stress increases from a surface of the spring wire in a depth slrection, (i) frst residual stress peak in which an absolute value of the compressive residual stress is at ‘maximum, (ii) a second residual stress peak formed ‘between the residual stress increase part and the fist ‘residual stress peak, wherein amogninide of an absolute value of the compressive residual stress of the second residual stress peak is higher than a magnitude of an absolute value of the compressive residual stress a the surface of the spring wire, and (iv) a residual stress ‘decrease pat in which an absolute value ofthe eompres- sive residual siress decreases from the first residual stress peak in the depth dirsetion of the spring wire nd wherein the residual stress deereae part includes «region ‘sta depth exceeding a permissible pit depth ofthe spring Wire at which a magnitude of the compressive residual stress is equivalent to the magnitude ofthe compressive ‘residual stres tthe surice ofthe spring Wie 2. The manufacturing, method according t0 clsim 1, wherein the fist shot peening process and the second shot peetting process are carried ot in a sate in which the spring \Wireis kept at a processing temperature of 150" C. 0 350°C. 3. The manuficturing method according © claim 2, ‘wherein the processing temperature inthe frst shot peening process is higher thaa the processing temperature i the xec- ‘ond shot peening process. “4. The manuficturing method according to claim 3, wherein a Kinetic enerzy of the frst shot in the first shot peeting proces is greuter than a kinetic energy ofthe second shot inthe second shot peening process.

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