DESCRIPTION
ROLLED ROUND STEEL MATERIAL FOR STEERING RACK BAR AND
STEERING RACK BAR
TECHNICAL FIELD
[0001]
The present invention relates to a rolled round steel material for a steering rack
bar (hereafter, may also be referred to as a "rolled round steel material for a rack bar")
and to a steering rack bar (hereafter, may also referred to as a "rack bar").
[0002]
It is noted that the "rolled round steel material" refers to steel material whose
cross-section is processed into a circular shape by rolling.
BACKGROUND ART
[0003]
Among automotive parts, a rack bar, which is used for a steering apparatus, is
an important part which steers the travelling direction of the automobile and also serves
as a framework to link the left and right wheels so that if it fails, steering operation will
be disabled. For this reason, high reliability is required for steel materials to be used
as a rack bar.
[0004]
A rack bar has been produced by subjecting a rolled round steel material of
middle carbon steel to thermal refining treatment by quenching and tempering, then to
drawing as needed, and further to boring and gear tooth shaping (forming of a tooth
shaped part) by machining, and subjecting the tooth shaped part to induction quenching
and tempering.
[0005]
For that reason, it is required for a rack bar that even when subjected to an
excessive load, a crack generated in an induction hardened layer should not propagate in
2
the base metal, leading to rupture.
[0006]
Further, a rack bar is subjected to a deep hole machining in the longitudinal
direction of a radially central part.
[0007]
Therefore, to achieve productivity and characteristics of component at the same
time, a round steel material to be used as a starting material for a rack bar is required of
excellent machinability when machining a deep hole, and excellent base metal impact
characteristics (base metal toughness) for resisting the propagation of a generated crack.
[0008]
As the steel material to be used for such a rack bar, the present inventors have
proposed, for example, the following steel materials.
[0009]
They proposed, in Patent Document 1, a rolled steel material for induction
quenching having: a chemical composition consisting of, in mass%, C: 0.38 to 0.55%,
Si: not more than 1.0%, Mn: 0.20 to 2.0%, P: not more than 0.020%, S: not more than
0.10%, Cr: 0.10 to 2.0%, Al: not more than 0.10%, and N: 0.004 to 0.03%, with the
balance being Fe and impurities, wherein the value of fn1 which is represented by a
Formula [fn1 = C + (1/lO)Si + (1/5)Mn + (5/22)Cr + 1.65V- (5/7)S] (where C, Si, Mn,
Cr, V and S respectively represents content in mass% of each element) is not more than
1.20; and a microstructure consisting of ferrite, lamellar pearlite, and spheroidal
cementite, wherein an average grain diameter of ferrite is not more than 1 0 J..lm, an area
proportion of the microstructure occupied by lamellar pearlite having a lamellar spacing
of not more than 200 nm of the entire lamellar pearlite is 20 to 50%, and a number of
particles of spheroidal cementite is not less than 4x 105 /mm2.
[0010]
It is noted that the rolled steel material for induction quenching may further
contain one or more elements selected from Cu, Ni, Mo, Ti, Nb, and V.
[0011]
They proposed, in Patent Document 2, a rolled steel material for induction
3
quenching having: a chemical composition consisting of, in mass%, C: 0.38 to 0.55%,
Si: not more than 1.0%, Mn: 0.20 to 2.0%, P: not more than 0.020%, S: not more than
0.10%, Cr: 0.10 to 2.0%, Al: 0.010 to 0.10%, and N: 0.004 to 0.03%, with the balance
being Fe and impurities, wherein the value of Ceq which is represented by a Formula
[Ceq= C + (1110)Si + (1/5)Mn + (5/22)Cr + 1.65V • (5/7)S] (where C, Si, Mn, Cr, V
and S respectively represents content in mass% of each element) is not more than 1.20,
and a total content of Si, Mn, and Cr is 1.2 to 3 .5%; and a microstructure consisting of
ferrite, lamellar pearlite, and spheroidal cementite, wherein an average grain diameter of
the ferrite is not more than 1 0 J..l.m, an area proportion of the microstructure occupied by
the lamellar pearlite is not more than 20% (including 0%), and a number of particles of
spheroidal cementite is not less than 6x 1 05 /mm2•
[0012]
It is noted that the rolled steel material for induction quenching may further
contain one or more elements selected from Cu, Ni, Mo, Ti, Nb, and V.
LIST OF PRIOR ART DOCUMENTS
PATENT DOCUMENT
[0013]
Patent Document 1: JP2011-214130A
Patent Document 2: JP2011-241466A
DISCLOSURE OF THE INVENTION
PROBLEMS TO BE SOLVED BY THE INVENTION
[0014]
For the rolled steel materials proposed in Patent Documents 1 and 2 and
described above, there have been growing demands for further improving base metal
toughness for damage prevention, and machinability for machining a deep hole.
[0015]
The present invention has been made to meet the above described demands and
has its object to provide a rolled round steel material which can be suitably used as a
4
starting material for a rack bar to be subjected to induction quenching, and a rack bar
using the same. More specifically, it is an object of the present invention to provide a
rolled round steel material for a steering rack bar, which can achieve high base metal
toughness to halt a crack generated in a rack bar, and further exhibit excellent
machinability for machining a deep hole in the longitudinal direction of a radially
central part thereof, without necessarily needing expensive elements and even without
being subjected to thermal refining treatment, and a steering rack bar using the same.
[0016]
It is noted that "high base metal toughness" means that the base metal, in a
state of rolled steel material, has an impact value of not less than 120 J/cm2 at a test
temperature of 25°C in a Charpy impact test performed by using a standard specimen
having a width of 10 mm with a V notch having a notch depth of 2 mm, a notch angle of
45°, and a notch bottom radius of 0.25 mm (hereafter, referred to as a "V-notch Charpy
impact test specimen") defined in JIS Z 2242 (2005).
MEANS FOR SOLVING THE PROBLEMS
[0017]
The present inventors have conducted various laboratory studies on the means
of achieving high base metal toughness in a middle carbon steel without performing
thermal refining treatment and also securing excellent machinability in a central part.
[0018]
To be specific, first, means of improving base metal toughness with reference
to a microstructure consisting of ferrite and lamellar pearlite has been studied. As a
result ofthat, the following finding has been obtained.
[0019]
(A) Elongating ferrite finely and in a direction parallel with the rolling
direction, further transforming cementite in lamellar pearlite into spheroidal cementite
such that the lamellar pearlite is less than a specific proportion and spheroidal cementite
is contained by not less than a certain amount will increase the resistance to a crack
which propagates in a cross-section perpendicular to the rolling direction, thus making it
5
possible to improve base metal toughness.
[0020]
Next, effect of structure on the machinability when machining a deep hole has
been investigated with reference to microstructure consisting of ferrite and lamellar
pearlite. As a result, the following finding has been obtained.
[0021]
(B) When the amount of spheroidal cementite excessively increases in the
microstructure, chip treatability deteriorates and thereby cutting resistance increases,
thus resulting in deterioration of machinability. On the other hand, when a structure
includes not less than a specific proportion of lamellar pearlite, and in which the amount
of spheroidal cementite is suppressed to be less than a specific amount, the chip
treatability improves and consequently cutting resistance decreases, thereby improving
machinability.
[0022]
To improve base metal toughness and machinability, further, the effect of
component element has been studied. As a result, the following finding has been
obtained.
[0023]
(C) S combines with Mn to form MnS, and is elongated in the longitudinal
direction of steel material (direction parallel with the rolling direction), thereby
improving toughness. Furthermore, since when a specific amount of S is contained,
the chip treatability improves and thereby cutting resistance decreases, the
machinability improves.
[0024]
Then, based on the findings (A) to (C), further detailed study has been
conducted. As a result, the following important findings have been obtained.
[0025]
(D) As a rolled round steel material for a steering rack bar, the area where base
metal toughness for damage prevention is required is a region from a surface of the
round steel material to a position at 1/2 radius. Therefore, if the microstructure in the
6
region is composed of ferrite which is elongated finely and in the direction p~allel with
the rolling direction, lamellar pearlite which is limited to be not more than a specific
proportion, and not less than a specific amount of spheroidal cementite, it is possible to
obtain enough base metal toughness for damage prevention.
[0026]
(E) On the other hand, if in a central part of a rolled round steel material whose
microstructure consists of ferrite, lamellar pearlite, and spheroidal cementite, the
lamellar pearlite is contained in not less than a specific proportion, and the spheroidal
cementite is contained in less than a specific amount, excellent machinability can be
obtained.
[0027]
The present invention has been completed based on the above described
findings, and its gist lies in the rolled round steel material for a steering rack bar, and the
steering rack bar to be described below.
[0028]
(1) A rolled round steel material for a steering rack bar, having: a chemical
composition consisting of, in mass%, C: 0.38 to 0.55%, Si: not more than 1.0%, Mn:
0.20 to 2.0%, S: 0.005 to 0.10%, Cr: 0.01 to 2.0%, Al: 0.003 to 0.10%, N: 0.003 to
0.03%, Cu:O to 1.0%, Ni: 0 to 3.0%, Mo: 0 to 0.50%, Ti: 0 to 0.10%, Nb: 0 to 0.10%, V:
0 to 0.30%, Ca: 0 to 0.005%, and Pb: 0 to 0.30%, with the balance being Fe and
impurities, and P being not more than 0.030% in the impurities; and a microstructure
consisting of ferrite, lamellar pearlite, and cementite, wherein in a cross-section
perpendicular to a rolling direction: in a region from a surface to a position at 1/2 radius,
an average grain diameter of the ferrite is not more than 1 0 j..ll!l, an area fraction of the
lamellar pearlite is less than 20%, and a number of particles of spheroidal cementite
among the cementite is not less than 4x105/mm2
; and in a central part, an area fraction
of the lamellar pearlite is not less than 20%, and a number of particles of spheroidal
cementite among the cementite is less than 4x105/mm2
, and wherein in a cross-section
including a center line of the round steel material and parallel to the rolling direction: in
a region from a surface to a position at 1/2 radius, an average aspect ratio of the ferrite
7
grains is not less than 3.
[0029]
(2) The rolled round steel material for a steering rack bar according to the
above item (1), containing one or more elements selected from, in mass%, Cu: 0.10 to
1.0%, Ni: 0.10 to 3.0%, and Mo: 0.10 to 0.50%.
[0030]
(3) The rolled round steel material for a steering rack bar according to the
above item (1) or (2), containing one or more elements selected from, in mass%, Ti:
0.010 to 0.10%, Nb: 0.010 to 0.10%, and V: 0.010 to 0.30%.
[0031]
( 4) The rolled round steel material for a steering rack bar according to any of
the above items (1) to (3), containing one or more elements selected from, in mass%,
Ca: 0.0005 to 0.005%, and Pb: 0.05 to 0.30%.
[0032]
( 5) A steering rack bar, fabricated by using any of the rolled round steel
materials for a steering rack bar according to any of the above items (1) to (4) in a
non-thermally refined state.
[0033]
"Impurities" refer to those which are mixed from ores and scraps as the raw
material or manufacturing environments when steel material is industrially
manufactured.
[0034]
"Spheroidal cementite" refers to cementite whose ratio of the major diameter L
to the minor diameter W (L/W) is not more than 2.0.
[0035]
"Central part" refers to an area located within a distance up to 114 radius from
the center.
[0036]
"Used in a non-thermally refined state" means that something is used without
being· subjected to quenching and tempering, so-called "thermal refining treatment".
8
ADVANTAGEOUS EFFECTS OF THE INVENTION
[0037]
Since the rolled round steel material for a steering rack bar of the present
invention has high base metal toughness of an impact value of not less than 120 J/cm2 at
a test temperature of 25° C in a Charpy impact test performed by using a V-notch
Charpy impact test specimen, and further exhibits excellent machinability for machining
a deep hole in a central part thereof even without necessarily needing expensive V to be
contained and in a state of rolled round steel material even without being subjected to
thermal refining treatment, it is suitable for use as the starting material for a steering
rack bar.
[0038]
Further, the steering rack bar of the present invention can be obtained by using
the above described rolled round steel material for a steering rack bar in a non-thermally
refined state.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039]
[Figure 1] Figure 1 schematically illustrates the orientation of a notch of a V-notch
Charpy impact test specimen taken from a steel bar in Example 1.
[Figure 2] Figure 2 illustrates the shape of a specimen taken from a drawn steel bar and
simulating a steering rack bar used in a 3-point bending test of Example 2. In Figure 2,
(a) shows a front view (general view), (b) a side view, and (c) an enlarged view of a
tooth shaped part in the "A" -"A" cross-section. Note that the unit of dimension is
"mm" in (a) to (c) in Figure 2.
[Figure 3] Figure 3 schematically illustrates a 3-point bending test conducted m
Example2.
MODE FOR CARRYING OUT THE INVENTION
[0040]
9
Hereafter, each requirement of the present invention will be described in detail.
Note that"%" of the content of each element means "mass%" in the description below.
[0041]
1. Chemical composition:
C: 0.38 to 0.55%
C (carbon) has the effect of improving the strength and induction hardenability
of steel, and the strength of a hardened layer formed by induction quenching. To
achieve these effects, C is contained in an amount of not less than 0.3 8%. On the other
hand, when C content exceeds 0.55%, base metal toughness deteriorates. Therefore, C
content is specified to be 0.38 to 0.55%. Note that, to stably achieve the above
described effects, C content is preferably not less than 0.40%. Moreover, C content is
preferably not more than 0.51 %.
[0042]
Si: not more than 1.0%
Si (silicon) is a deoxidizing element and is also an element that increases the
strength of ferrite by solid solution strengthening. However, when Si content exceeds
1.0%, the machinability deteriorates thereby making it difficult to machine a deep hole.
Therefore, Si content is specified to be not more than 1.0%. Si content is preferably
not more than 0.8%.
[0043]
Note that since Alto be described later has also deoxidizing effect, there is no
need of setting a lower limit for Si content. However, to reliably ensure strength by
utilizing the solid solution strengthening effect of Si as described above, Si content is
preferably not less than 0.03%, and more preferably not less than 0.1 0%.
[0044]
Mn: 0.20 to 2.0%
Mn (manganese) has the effect of combining with S to form MnS and thereby
improving machinability, especially chip treatability when machining a deep hole, and
further, elongated MnS is effective in suppressing the propagation of crack and thereby
improving toughness. Moreover, Mn is an element that is effective in improving
10
induction hardenability and also an element that increases the strength of ferrite through
solid solution strengthening. To achieve these effects, Mn is contained in an amount of
not less than 0.20%. On the other hand, if Mn is contained in an amount of more than
2.0%, machinability of steel deteriorates thereby making it difficult to machine a deep
hole. Therefore, Mn content is specified to be 0.20 to 2.0%. Note that to stably
achieve the above described effects while suppressing the alloying cost low, Mn content
is preferably not less than 0.40%, and is also preferably not more than 1.50%.
[0045]
S: 0.005 to 0.10%
S (sulfur) is an important element in the present invention. S has the effect of
combining with Mn to form MnS, thereby improving machinability, especially chip
treatability when machining a deep hole, and further, elongated MnS has the effect of
suppressing the propagation of crack and thereby improving toughness. To achieve
these effects, Sis contained in an amount of not less than 0.005%. On the.other hand,
when S content increases thus forming too much amount of MnS, toughness of steel
will be deteriorated on the contrary. Therefore, S content is specified to be 0.005 to
0.10%. Note that S content is preferably not less than 0.010%, and more preferably
not less than 0.015%. Moreover, S content is preferably not more than 0.08%.
[0046]
Cr: 0.01 to 2.0%
Since Cr (chromium) is an element that is effective in improving induction
hardenability and also an element that increases the strength of ferrite through solid
solution strengthening, Cr needs to be contained in an amount of not less than 0.01 %.
However, if Cr content exceeds 2.0%, machinability of steel deteriorates thereby
making it difficult to machine a deep hole. Therefore, Cr content is specified to be
0.01 to 2.0%. Note that Cr content is preferably not less than 0.05%, and more
preferably not less than 0.1 0%. Further, Cr content is preferably not more than 1.8%.
[0047]
Al: 0.003 to 0.10%
AI (aluminum) has a deoxidizing effect and also combines with N in steel to
11
form AIN, thereby contributing to the refinement of base metal structure. To achieve
these effects, AI is contained in an amount of not less than 0.003%. On the other hand,
when AI content exceeds 0.1 0%, induction hardenability of steel is significantly
deteriorated, and further, deterioration of base metal toughness is caused. Therefore,
AI content is specified to be 0.003 to 0.10%. Note that AI content is preferably not
more than 0.08%. On the other hand, in ~ viewpoint of preventing the coarsening of
grain during induction quenching, to ensure the formation of AIN described above, AI
content is preferably not less than 0.005%, and more preferably not less than 0.010%.
[0048]
N: 0.003 to 0.03%
N (nitrogen) combines with AI in steel to form AIN, thereby contributing to the
refinement of base metal structure. To achieve these effects, N is contained in an
amount of not less than 0.003%. On the other hand, when N content exceeds 0.03%,
deterioration of base metal toughness will result. Therefore, N content is specified to
be 0.003 to 0.03%. Note that N content is preferably not less than 0.004%, and is also
preferably not more than 0.02%.
[0049]
One of the rolled round steel materials for a steering rack bar of the present
invention has a chemical composition consisting of the above described elements of C
toN, with the balance being Fe and impurities, wherein Pin the impurities is not more
than 0.030%.
[0050]
P: not more than 0.030%
P (phosphor) is contained in steel as an impurity and causes grain boundary
segregation and central segregation, thereby causing deterioration of base metal
toughness. Particularly, when P content exceeds 0.030%, the deterioration of base
metal toughness will become significant. Therefore, P content is specified to be not
more than 0.030%. Note that P content is preferably not more than 0.020%.
[0051]
A rolled round steel material for a steering rack bar of the present invention
12
may contain, in addition to the above described each element, one or more elements
selected from Cu, Ni, Mo, Ti, Nb, V, Ca, and Pb.
[0052]
Hereafter, working effects of the above described Cu, Ni, Mo, Ti, Nb, V, Ca,
and Pb, which are optional elements, and reasons to limit their contents will be
described.
[0053]
Since Cu, Ni, and Mo have the effects of improving induction hardenability of
steel and yet further improving base metal toughness thereof, these elements may be
contained to achieve those effects. Hereafter, detailed description will be made on this
point.
[0054]
Cu: 0 to 1.0%
Since Cu (copper) has the effects of improving induction hardenability of steel
and also improving base metal toughness thereof, Cu may be contained for
improvement of base metal toughness. However, when Cu content exceeds 1.0%,
machinability of steel will deteriorate, making it difficult to machine a deep hole.
Therefore, the content of Cu, if contained, is specified to be not more than 1.0%. Note
that Cu content is preferably not more than 0.80%.
[0055]
On the other hand, to stably achieve the effect of Cu of improving base metal
toughness, Cu content is preferably not less than 0.05%, and more preferably not less
than 0.10%.
[0056]
Ni: 0 to 3.0%
Since Ni (nickel) has the effects of improving induction hardenability of steel
and also improving base metal toughness thereof, Ni may be contained for improvement
of base metal toughness. However, when Ni content exceeds 3.0%, machinability of
steel will deteriorate, making it difficult to machine a deep hole. Therefore, the
content ofNi, if contained, is specified to be not more than 3.0%. Note that Ni content
13
is preferably not more than 2.0%.
[0057]
On the other hand, to stably achieve the effect of Ni of improving base metal
toughness, Ni content is preferably not less than 0.05%, and more preferably not less
than 0.10%.
[0058]
Mo: 0 to 0.50%
Since Mo (molybdenum) has the effects of improving induction hardenability
of steel and also improving base metal toughness thereof, Mo may be contained for
improvement of base metal toughness. However, when Mo content exceeds 0.50%,
machinability of steel will deteriorate, making it difficult to machine a deep hole.
Therefore, the content of Mo, if contained, is specified to be not more than 0.50%.
Note·that Mo content is preferably not more than 0.40%.
[0059]
On the other hand, to stably achieve the effect of Mo of improving base metal
toughness, Mo content is preferably not less than 0.05%, and more preferably not less
than 0.10%.
[0060]
Note that the above described Cu, Ni, and Mo may be contained in only one
element thereof, or two or more elements in combination. Note that although the total
content of these elements may be 4.50%, it is preferably not more than 3.20%.
[0061]
Since Ti, Nb, and V have the effect of refining grains, these elements may be
contained to achieve those effects. Hereafter, detailed description will be made on this
point.
[0062]
Ti: 0 to 0.10%
Since Ti (titanium) has the effect of combining with C or N in steel to form
carbide, nitride, or carbo-nitride, thereby refining grains during hot rolling or induction
quenching, Ti may be contained for grain refinement. However, when Ti is contained
14
in an amount of more than 0.1 0%, although refinement of grain can be expected,
deterioration of toughness will result. Therefore, the content of Ti, if contained, is
specified to be not more than 0.10%. Note that in the viewpoint of suppressing
toughness deterioration, Ti content is preferably not more than 0.08%.
[0063]
On the other hand, to stably achieve the grain refinement effect ofTi, above all,
the grain refinement effect thereof during induction quenching, Ti content is preferably
not less than 0.010%, and more preferably not less than 0.015%.
[0064]
Nb: 0 to 0.10%
Nb (niobium) has the effect of combining with CorN in steel to form carbide
or carbo-nitride, and thereby refining grains. Moreover, Nb also has the effect of
increasing the strength of steel. However, when Nb content exceeds 0.1 0%, the effect
thereof will be saturated, thereby not only causing increase of cost, but also leading to
deterioration of toughness. For that reason, the content of Nb, if contained, is
specified to be not more than 0.10%. Note that Nb content is preferably not more than
0.08%.
[0065]
On the other hand, to stably achieve the grain refinement effect of Nb, Nb
content is preferably not less than 0.010%, and more preferably not less than 0.015%.
[0066]
V: 0 to 0.30%
V (vanadium) has the effect of combining with CorN in steel to form carbide
or carbo-nitride, and thereby refining grains. Moreover, V also has the effect of
increasing the strength of steel. However, when V content exceeds 0.30%, the effect
thereof will be saturated, thereby not only causing increase of cost, but also leading to
deterioration of toughness. For that reason, the content of V, if contained, is specified
to be not more than 0.30%. Note that V content is preferably not more than 0.25%.
[0067]
On the other hand, to stably achieve the grain refinement effect of V, V content
15
is preferably not less than 0.010%, and more preferably not less than 0.020%.
[0068]
Note that the above described Ti, Nb, and V may be contained in only one
element thereof, or two or more elements in combination. Note that although the total
content of these elements may be 0.50%, it is preferably not more than 0.41 %.
[0069]
Since if Ca and Pb are contained, further improvement of machinability can be
expected, these elements may be contained to achieve this effect. Hereafter, detailed
description will be made on this point.
[0070]
Ca: 0 to 0.005%
Ca (calcium) has the effect of improving machinability of steel. For this
reason, Ca may be contained as needed. However, when Ca content exceeds 0.005%,
hot workability deteriorates, thereby reducing productivity. Therefore, the content of
Ca, if contained, is specified to be not more than 0.005%. Ca content is preferably not
more than 0.0035%.
[0071]
On the other hand, to stably achieve the machinability improvement effect of
Ca, Ca content is preferably not less than 0.0005%.
[0072]
Pb: 0 to 0.30%
Pb (lead), as well as Ca, has the effect of improving machinability of steel
when contained therein. For this reason, Pb may be contained as needed. However,
when Pb content exceeds 0.30%, the aforementioned machinability improvement effect
will be saturated, and hot workability will excessively deteriorate, thus making the
production thereof difficult. Therefore, the content of Pb, if contained, is specified to
be not more than 0.30%.
[0073]
On the other hand, to stably achieve the machinability improvement effect, Pb
content is preferably not less than 0.05%.
16
[0074]
2. Microstructure:
The microstructure of a rolled round steel material for a steering rack bar of the
present invention consists of ferrite, lamellar pearlite, and cementite.
[0075]
In the case of a rolled round steel material for a steering rack bar of the present
invention, in a cross-section perpendicular to a rolling direction, when an average grain
diameter of ferrite in a region from a surface of the round steel material to a position at
1/2 radius is more than 10 J.LID., it is difficult to obtain targeted base metal toughness.
Therefore, the average grain diameter of ferrite is specified to be not more than 10 J.Lm.
Note that the average grain diameter of ferrite is preferably not more than 8 J.Lin.
[0076]
Although the average grain diameter of ferrite is preferably as small as possible
in enhancing grain refinement, forming grains of submicron order requires special
processing condition or equipment, and therefore is difficult to be industrially realized.
Therefore, a lower limit of the average grain diameter of ferrite as the size that can be
industrially realized is about 1 J.Lm.
[0077]
The above described average grain diameter of ferrite may be determined, for
example, by respectively determining ferrite grain diameters at three locations including
a position at 1 mm from the surface of the rolled round steel material, a position at 1/4
radius from the surface (hereafter, referred to as "R/4 position", "R" referring to radius,
and the same applying hereafter), and a position at 112 radius from the surface (hereafter,
referred to as "R/2 position"), and thereafter taking an arithmetic average of the ferrite
grain diameters at the three locations.
[0078]
In the case of a rolled round steel material for a steering rack bar of the present
invention, when in a cross-section perpendicular to a rolling direction, the area fraction
of lamellar pearlite in a region from a surface to a position at 112 radius is not less than
20%, deterioration of base metal toughness will result. Therefore, the area fraction of
17
lamellar pearlite is specified to be less than 20%. The area fraction of lamellar pearlite
is preferably not more than 15%, and may also be 0%.
[0079]
The area fraction of lamellar pearlite may be determined, for example, by
respectively determining area fractions oflamellar pearlite at three locations including a
position at 1 mm from the surface of the rolled round steel material, an R/4 position,
and an R/2 position, and thereafter taking an arithmetic average of the area fractions of
lamellar pearlite at the three locations.
[0080]
In the case of a rolled round steel material for a steering rack bar of the present
invention, when in a cross-section perpendicular to the rolling direction, the number of
particles of spheroidal cementite in a region from the surface to a position at 1/2 radius
is less than 4xl05/mm2, deterioration of base metal toughness will result. Therefore,
the above described number of particles of spheroidal cementite is specified to be not
less than 4x105/mm2• The number of particles of spheroidal cementite is preferably
not less than 5x105/mm2 and is also preferably not more than l.Ox1012/mm2•
[0081]
The number of particles of spheroidal cementite may be determined, for
example, by respectively determining numbers of particles of spheroidal cementite at
three locations including a position at 1 mm from the surface of the rolled round steel
material, an R/4 position, and an R/2 position, and thereafter taking an arithmetic
average ofthe numbers of particles of spheroidal cementite at the three locations.
[0082]
In the case of a rolled round steel material for a steering rack bar of the present
invention, when in a cross-section perpendicular to the rolling direction, the area
fraction of lamellar pearlite in a central part is less than 20%, toughness will increase,
thereby causing deterioration of chip treatability. Therefore, the area fraction of
lamellar pearlite is specified to be not less than 20%. The area fraction of lamellar
pearlite is preferably not less than 25%, and is also preferably not more than 80%.
[0083]
18
The area fraction of lamellar pearlite may be determined by, for example,
respectively determining area fractions of lamellar pearlite at two locations including a
position at 3/4 radius from the surface of the rolled round steel material (hereafter,
referred to as "3R/4 position"), and a center position, and thereafter taking an arithmetic
average of the area fractions of lamellar pearlite at the two locations.
[aa84]
In the case of a rolled round steel material for a steering rack bar of the present
invention, when in a cross-section perpendicular to the rolling direction, the number of
particles of spheroidal cementite in a central part is not less than 4x 1 as /mm2, toughness
will increase, thereby causing deterioration of chip treatability. Therefore, the number
of particles of spheroidal cementite in a central part is specified to be less than
4x 1 as /mm2• Although the number of particles of spheroidal cementite may be a/mm2,
it is preferably not less than lx102/mm2, and is also preferably not more than
3xlas/mm2•
[aa85]
The number of particles of spheroidal cementite may be determined by, for
example, respectively determining numbers of particles of spheroidal cementite at two
locations including a 3R/4 position and a center position of the rolled round steel
material, and thereafter taking an arithmetic average of the numbers of particles of
spheroidal cementite at the two locations.
[aa86]
In the case of a rolled round steel material for a steering rack bar of the present
invention, when in a cross-section including a center line of the round steel material and
parallel to the rolling direction, an average aspect ratio of the ferrite grains in the region
from the surface to the position at 1/2 radius is less than 3, a crack becomes likely to
propagate in a cross-section perpendicular to the rolling direction, thereby causing
deterioration of toughness. Therefore, the average aspect ratio of ferrite grains is
specified to be not less than 3. The average aspect ratio of ferrite grains is preferably
not less than 4, and is also preferably not more than 45.
[aa87]
19
The average aspect ratio of ferrite grains may be determined by, for example,
respectively determining average aspect ratios of ferrite grains at three locations
including a position at 1 mm from the surface of the rolled round steel material, an R/4
position, and an R/2 position, and thereafter taking an arithmetic average of the average
aspect ratios at the three locations.
[0088]
The above described microstructure of a rolled round steel material for a
steering rack bar of the present invention can be obtained by, for example, hot rolling
and cooling a workpiece having an already described chemical composition in a manner
as described below.
[0089]
As the hot rolling method, a fully continuous hot rolling method with two or
more rolling steps is suitable for producing a rolled round steel material for a steering
rack bar of the present invention. Therefore, the following description will be made
based on rolling by the fully continuous hot rolling method (hereafter, simply referred to
as "fully continuous hot rolling").
[0090]
A workpiece having an already described chemical composition is heated to a
temperature range of 670 to 850°C, and thereafter the fully continuous hot rolling is
started.
[0091]
When the heating temperature is higher than 850°C, it becomes likely that
strain is released so that in a cross-section perpendicular to the rolling direction, one or
more of the average ferrite grain diameter, the area fraction of lamellar pearlite, and the
number of particles of spheroidal cementite in a region from a surface to a position at
112 radius may deviate from the conditions described in the cross-section of "2.
Microstructure". Moreover, when the heating temperature is less than 670°C, in the
above described cross-section, one or more of the area fraction of lamellar pearlite and
the number of particles of spheroidal cementite in a central part may deviate from the
above described microstructure conditions.
20
[0092]
Note that in the heating in the temperature range of 670 to 850°C, heating
treatment for long hours may be performed not only to increase the temperature of the
workpiece (starting material) to a predetermined range, but also to uniformize the
temperature distribution in the cross-section of the starting material. In such a case,
ferrite decarburization may occur on the surface of the starting material. Therefore, to
suppress the ferrite decarburization, heating time in the above described temperature
range is preferably not more than 3 hours.
[0093]
The fully continuous hot rolling is preferably performed in such a way to
satisfy the following conditions [ 1] and [2].
[0094]
[1] The surface temperature of the workpiece -is 500 to 810°C, a cumulative
reduction of area in a temperature range of 650 to 810°C is not less than 30%, and
further the cumulative reduction of area in a temperature range of not less than 500°C to
less than 650°C is not less than 35%. However, the "surface temperature of the
workpiece" does not include the surface temperature of the workpiece during the
intermediate cooling step to be described below.
[0095]
[2] Supposing that "v(m/s)'i be a velocity of workpiece at the end of the fully
continuous hot rolling, that is, an exit side of the final rolling mill (hereafter, referred to
as "finishing velocity"), "Rd(%)" be a total reduction of area of the fully continuous hot
rolling, and "T(°C)" be the heating temperature of the workpiece, the following Formula
fn(1) satisfies the condition of not less than 0:
fn(l) = v·Rd/100- (1000- T)/100
where, the reduction of area (%) when the workpiece having a cross sectional area A is
rolled to a cross sectional area A' is determined by the formula of {(A - A')/ A} x 100.
Moreover, "total reduction of area" refers to a value(%) to be determined by a formula
of { (Ao - Ar)/ Ao} x 100 when supposed that the cross sectional area before rolling of the
workpiece in the fully continuous hot rolling be Ao, and the cross sectional area after
21
exit of the final rolling mill be Ar.
[0096]
Regarding [1], when the temperature of the workpiece is more than 810°C
during rolling, it becomes likely that strain is released so that in a cross-section
perpendicular to the rolling direction, one or more of the average ferrite grain diameter,
the area fraction of lamellar pearlite, and the number of particles of spheroidal cementite
in a region from a surface to a position at 1/2 radius may deviate from the conditions
described in the cross-section of "2. Microstructure". Moreover, when the above
described temperature is less than 500°C, the load on the mill significantly increases,
and cracking is likely to occur during rolling. Therefore, the surface temperature of
the workpiece is preferably 500 to 81 0°C during rolling.
[0097]
Further, when the cumulative reduction of area in a temperature range of 650 to
81 0°C becomes less than 30%, in a cross-section perpendicular to the rolling direction,
one or more of the average ferrite grain diameter, the area fraction of lamellar pearlite,
and the number of particles of spheroidal cementite in a region from a surface to a
position at 1/2 radius may deviate from the microstructure conditions described above.
The upper limit of the cumulative reduction of area in the range of 650 to 81 0°C will be
about 99.5% to prevent a large scale extension of production line.
[0098]
Moreover, when the cumulative reduction of area in a temperature range of not
less than 500°C to less than 650°C becomes less than 35%, one or more of the average
aspect ratio of ferrite grains in a region from a surface to a position at 1/2 radius in a
cross-section including the center line of the workpiece and parallel to the rolling
direction, and the number of particles of spheroidal cementite in a region from a surface
to a position at 1/2 radius in a cross-section perpendicular to the rolling direction may
deviate from the microstructure conditions described above. The upper limit of the
cumulative reduction of area in the range of not less than 500°C to less than 650°C will
be about 80% to prevent a large scale extension of production line.
[0099]
22
[2] is an empirically obtained formula to make the microstructure of a central
part in a cross-section perpendicular to the rolling direction be one described in the
cross-section of "2. Microstructure". When fn(1) becomes less than 0, in a
cross-section perpendicular to the rolling direction, one or more of the area fraction of
lamellar pearlite and the number of particles of spheroidal cementite in a central part
may deviate from the microstructure conditions described above.
[0100]
When rolling a rolled round steel material for a rack bar in the present
invention, intermediate cooling such as water cooling may be performed in a midway
step. Note that in the intermediate cooling step, the surface temperature of the
workpiece may temporarily become less than 500°C. However, even if the surface
temperature of the workpiece becomes less than 500°C due to the cooling, the effect of
the temporal decrease of the surface temperature of the workpiece to less than 500°C by
cooling may be neglected if the following rolling step is started after the temperature is
recuperated to a temperature not less than 500 °C by sensible heat within the workpiece.
Moreover, if untransformed austenite in the workpiece has transformed into a hard
phase such as martensite and bainite, the microstructure defined in the present invention
may not be obtained. To prevent this, cooling in the intermediate cooling step is
preferably performed in such a manner that a time period ~t until the surface
temperature of the workpiece recuperates to a temperature of not less than 500°C after it
temporarily becomes less than 500°C is not more than 10 seconds. Further, for aiming
at production by a more stable fully continuous hot rolling, an intermediate cooling step
in which ~t is not more than 8 seconds is preferable.
[0101]
After being processed into a predetermined shape by being subjected to the
fully continuous hot rolling as described above, the workpiece is preferably subjected to
final cooling at a condition in which the cooling rate of the surface is 0.5 to 200°C/s in a
temperature range to 500°C.
[0102]
When the cooling rate of the surface is less than 0.5°C/s after the end of fully
23
continuous hot rolling, in a cro~s-section perpendicular to the rolling direction, one or
more of the area fraction of lamellar pearlite and the number of particles of spheroidal
cementite of a central part may deviate from the conditions described in the
cross-section of "2. Microstructure". On the other hand, when the cooling rate of the
surface exceeds 200°C/s, untransfonned austenite may trans~onn into a hard phase such
as martensite and bainite.
[0103]
Hereafter, the present invention will be described in more detail by means of
examples.
EXAMPLE
[0104]
(Example 1)
Square billets (160 mm square and 10 m length) made of Steels A to W having
chemical compositions shown in Table 1 were prepared.
[0105]
[Table 1]
24
,..-,
.0.. ... Table 1
0
...0.....\..
I:I1
Pl g.
Steel Chemical composition (mass%) Balance: Fe and impurities
c Si Mn p s Cr AI N Cu Ni Mo Ti Nb v Ca Pb
A 0.42 0.65 0.45 0.009 0.030 1. 23 0.028 0.006 - - - - - - - -
B 0.45 0.80 0. 75 0. 010 0.050 0. 09 0.042 0. 013 - - - - - - - - 0
1-+) c 0.48 0. 11 1. 45 0.007 0.073 0. 99 0.019 0.008 - - - - - - - - g.
0
en
0 0.43 0. 41 0.43 0.013 0.015 1. 60 0.050 0. 004 - - - - - - - -
.g E 0.45 0. 21 0. 74 0.014 0.029 0.11 0.038 0.007 - - - - - - - - F 0.54 0.53 0.62 0. 018 0.046 0. 15 0.025 0.008 - - - - - - - -
!:l 0 G 0.40 0. 12 1. 20 0. 006 0. 063 0.63 0. 036 0. 005 - - - - - - - -
..c....T...... H 0.53 0.22 0.58 0. 011 0.029 0.44 0. 021 0.007 0.15 - - - - - - - ......
0
r+ en
I 0.44 0.34 0.77 0.007 0.008 0.10 0.028 0.006 - 0.13 - - - - - -
J 0. 39 0.13 0. 81 0.009 0.059 0.52 0.030 0.015 - - 0.08 - - - - -
~
~
K 0.45 0.27 0.93 0.005 0.025 0.05 0.040 0.018 - - 0.10 0.010 - - - -
L 0. 49 0.43 0. 65 0.007 0.038 I 0.07 0.072. 0. 005 - - - - 0.020 - - - g. t-.:) ......
01 a ...... a 0
Pl
M 0.47 0.63 1. 21 o.oos· 0.042 0.22 0.034 0.010 - - - - - 0. 098 - -
I N 0.46 0.34 0.87 0. 005 0. 025 0. 12 0.063 0. 011 - - - - - - 0.002 -
0 0. 41 0. 72 1. 02 0.003 0.020 1. 01 0.018 0. 013 - 0.21 - - - - - 0.13
p 0.48 0.27 0. 74 0.003 0.033 0. 12 0. 031 0.007 - - - - 0. 019 - 0.002 -
Q 0. 51 0.38 0. 41 0.023 0.077 0.33 0.022 0.009 0.23 -: - - 0.021 - 0.003 -
en r+ R *<>.58 0.22 0.66 0. 006 0.053 0.99 0. 022 0.006 - - - - - - - -
0
~ s 0.44 *1. 21 0. 75 0. 011 0.027 0.92 0.019 0. 003 - 0. 08 - - - - - -
cT T 0. 45 0. 55 *2.20 0. 007 0.033 1. 03 0. 028 0.006 - - - - - 0.033 - -
~ u 0.40 0.20 0.55 *0.052 0. 070 0. 12 0.044 0.005 - - - - - - - 0.15 I
::r'
.~.... .
::s
OQ
v 0.38 0. 41 0. 74 0.008 *0.003 0. 06 0.037 0. 010 - - - - - - - -
w 0.53 0.43 0. 81 0. 013 0.022 *2. 18 0.034 0.012 - - - - - - - -
"*" indicates deviation from the chemical composition condition defined in the present invention.
Pl
.0.......
!3 0
r+
~
0
1-+)
VJ
~
mm at conditions shown as Test Nos. 1 to 31 in Table 2 by a fully continuous hot rolling
line with a cooling facility. To be specific, after being processed into a diameter of 60
mm by a rough rolling mill train, and further into a diameter of 50 mm by an
intermediate rolling mill train, each square billet was processed into a steel bar having a
diameter of 34 mm by a finish rolling mill train, thus performing hot rolling of which
"total reduction of area: Rd" is 96.4%.
[0107]
The cumulative reduction of area when a square billet of'160 mm square was
processed into a diameter of 50 mm by a rough rolling mill train and an intermediate
rolling mill train was 92.3%. Moreover, the cumulative reduction of area when the
workpiece that exited the rough rolling mill train and had a diameter of 60 mm was
processed into a steel bar having a diameter of 34 mm by an intermediate rolling mill
train and a finish rolling mill train was 67 .9%. The cumulative reduction of area when
a square billet of 160 mm square was processed into a steel bar having a diameter of 34
mm by a rouih rolling mill train, an intermediate rolling mill train, and a finish rolling
mill train, that is, the total reduction of area was 96.4%.
[0108]
- Rough rolling mill train: consisting of 8 rolling mills,
- Intermediate rolling mill train: consisting of 4 rolling mills,
- Finish rolling mill train: consisting of 4 rolling mills, and
- Cooling zone: installed between the 8th rolling mill of the rough rolling mill
train and the first rolling mill of the intermediate rolling mill train, and between the 4th
rolling mill of the intermediate rolling mill train and the first rolling mill of the finish
rolling mill train.
[0109]
Note that the surface temperature of the workpiece during rolling and the
surface temperature of the workpiece during the cooling procedure after the end of
continuous rolling were measured by using a radiation thermometer, and a time period
~t' from the end of the cooling step in midway to the start of the following rolling step
was measured.
26
[0110]
After the end of continuous rolling, that is, after rolling by the 4th rolling mill
of the finish rolling mill train ended, the workpiece was finally cooled to 500°C while
controlling a cooling rate such as by natural (air) cooling or wind cooling in the
atmosphere. Note that cooling thereafter was conducted by cooling in the atmosphere.
[0111]
In Table 2, the rough rolling mill train, intermediate rolling mill train, and
finish rolling mill train are denoted by "Rough train", "Intermediate train", and "Finish
train", respectively.
[0112]
Note that "Entering temperature" and "Exiting temperature" in each column of
the Rough train, Intermediate train, and Finish train respectively indicate surface
temperatures of the workpiece measured by means of a radiation thermometer at time
points immediately before the workpiece entered the rough train, the intermediate train,
and the finish train, and immediately after it exited therefrom, and the cooling rate to
500°C after rolling was determined from the surface temperature of the workpiece
measured by means of a radiation thermometer and the cooling time to 500°C.
[0113]
Note that for Test Nos. 1 to 31, the time period .1t' from the end of the cooling
step in midway to the start of the following rolling step was not more than 8 seconds in
any case.
[0114]
[Table 2]
27
,---,
.0... ... Table2
.......
...V.....I.
'"Ij
0
Test Heating Rough train lnlermediate train Rnish train Cumulative Cumulative reduction of Total Rnishing Cooling rate Steel
~I Entering EJiting Reduction Entering EJiting Reduction Entering EJiting Kecluction reduction of aea In not less than reduction of speed lv] fn (1) to soo·c No. ure[T] tempenmue temperature of area temperature ~ of area temperature ~ of area area in 650 to 50D"C to less than area [Rd] (m/s} ("Cis) ('C) ('C) ('C) . (%} ('C) ("C) (%} ("C) ('C) (%} 810"C(%} 650'C(%) (%}
'"1
(1)
Pl g.
1 A 805 765 745 89.0 655 680 30.6 580 635 53.8 92.3 53.8 96.4 3,1 1.0 20
2 B 815 170 780 89.0 665 670 30.6 600 635 53.8 92.3 53.8 96.4 3.3 1.3 25
3 c 795· 766 765 89.0 660 675 30.6 590 640 53.8 92.3 63.8 96.4 2.9 0. 7 25
4 0 800 755 760 89.0 620 645 30.6 590 620 53.8 89.0 67.9 96.4 3.0 0.9 30
0
1-+)
5 E 790 750 760 89.0 650 670 30.6 586 640 53.8 92.3 53.8 96.4 2.8 0.6 25
6 F 820 776 770 89.0 650 675 30.6 600 645 63.8 92.3 63.8 96.4 3.2 1. 3 20
so (1)
-Cll (1)
(1) ........
0"'
~
Cll - !:-.:> §" 00
Cll
0
-0"' Pl s· (1) p..
5" (1)
s.....
() a Cll 2 () a-
7 G 805 760 780 89.0 630 645 30.6 696 635 53.8 89.0 67.9 96.4 3.3 1.2 20
8 H 786 740 745 89.0 630 645 30.6 600 640 53.8 89.0 67.9 96.4 3. 1 0.8 25
9 J 810 770 780 89.0 665 680 30.6 690 635 53.8 92.3 53.8 96.4 3.0 1.0 25
1 0 J 810 766 765 89.0 650 666 30.6 545 585 53.8 92.3 53.8 96.4 2.9 0.9 25
1 1 K 790 750 780 . 89.0 626 646 30.6 590 625 63.8 89.0 67.9 96.4 2.9 0. 7 30
12 L 700 665 680 89.0 655 685 30.6 615 645 53.8 92.3 53.8 96.4 3.2 0.1 36
1 3 M BOO 760 770 89.0 655 670 30.6 580 625 53.8 92.3 53.8 96.4 3.1 1.0 25
1 4 N 800 755 760 89.0 625 646 30.6 595 630 53.8 89.0 67.9 96.4 3.0 0.9 20
1 6 0 810 765 770 89.0 626 640 30.6 680 626 53.8 89.0 67.9 96.4 3.0 1.0 20
1 6 p 805 750 765 89.0 660 685 30.6 600 635 53.8 92.3 53.8 96.4 2.6 0.6 25
1 7 Q 790 740 755 89.0 630 645 30.6 690 630 63.8 89.0 67.9 96.4 3.2 1.0 30
1 8 *R 790 750 745 89.0 626 640 30.6 600 625 53.8 89.0 67.9 96.4 3.0 o. 8 25
1 9 *S 810 760 770 89.0 660 685 30.6 605 640 53,8 92.3 53.8 96.4 2.8 0.8 35
20 *T 805 770 765 89.0 650 670 30.6 540 676 53.8 92.3 53.8 96.4 3.1 1.0 20
21 *U 770 740 740 89.0 710 730 30.6 600 640 53.8 92.3 53.8 96.4 3.5 1.1 26
22 *V 790 750 755 89.0 620 645 30.6 580 620 53.8 89.0 67.9 96.4 2.5 0.3 25
23 *W 810 770 780 89.0 705 726 30.6 600 635 53.8 02.3 63.8 96.4 3.2 1.2 30
24 E 870 830 850 89.0 7Hi 740 30.6 620 645 53.8 30.6 53.8 96.4 2.6 1.7 35
26 E 840 816 830 89.0 815 840 30.6 760 780 53.8 53.8 0. 0 96.4 7.9 6.0 30
26 E 680 630 640 89.0 600 640 30.6 580 630 53.8 0.0 96.4 96.4 1.4 -1.9 20
27 E 840 780 800 89.0 700 730 30.6 660 . 690 53.8 96.4 0.0 96.4 6.3 4.5 25
28 E BOO 760 770 89.0 600 620 30.6 600 616 53.8 89.0 67.9 96.4 0.8 -1.2 20
29 J 900 870 890 89.0 760 810 30.6 690 720 53.8 67.9 0.0 96.4 4.0 2.9 30
30 M 690 630 645 89.0 590 610 30.6 550 585 53.8 0.0 96.4 96.4 2.2 -1.0 35
31 p 710 660 680 89.0 610 645 30.6 655 700 53.8 93. 1 30.6 96.4 to. o 6. 7 35
fn (1) -v·Rd/100 ( 1 0 0 0 T) /1 0 0
"" indicates a Steel which is deviated from chemical composition defined in the present invention.
'"1
~(1) -(1) ::s
C...ll. . ........
(1)
characteristic, impact characteristic, and machinability were investigated in the
following methods.
[0116]
A specimen having a length of 20 mm was cut out from each steel bar having a
diameter of 34 mm, and was embedded in resin to be mirror polished such that a
cross-section of the specimen perpendicular to the rolling direction and a cross-section
including the center line and parallel to the rolling direction became test surfaces.
[0117]
The cross-section perpendicular to the rolling direction was first subjected to
etching by 3% nitric acid alcohol (Nital) to make the microstructure appear and was
observed with a scanning type electronic microscope (hereafter, referred to as "SEM")
to perform phase identification and investigate the average grain diameter of ferrite and
the area fraction of lamellar pearlite.
[0118]
To be specific, for the microstructure in a region from a surface to a position at
112 radius, metal structure of 3 locations including a position at 1 mm from the surface,
a position at 4.25 mm from the surface (R/4 position), and a position at 8.5 mm from the
surface (R/2 position) was observed by SEM at a magnification of 2000 times in 4 fields
of view at an interval of 90° in the circumferential direction for each location, which
amounts to a total of 12 fields of view, to identify the phases that constituted the
microstructure, and determine the average grain diameter of ferrite and the area fraction
of lamellar pearlite with image analysis software by using picked up images thereof.
Similarly, for the microstructure in a central part, metal structure of 2 locations
including a position at 12.75 mm from the surface (3R/4 position), and a center position
was observed by SEM at a magnification of 2000 times in 4 fields of view at an interval
of 90° in the circumferential direction for the 3R/4 position and one field of view for the
center position, which amounts to a total of 5 fields of view, to identify the phases that
constituted the microstructure, and determine the average grain diameter of ferrite and
the area fraction of lamellar pearlite with image analysis software by using picked up
images thereof.
29
[0119]
Next, the specimen which had been etched by Nital was mirror polished again,
and was thereafter etched by picric acid alcohol (Picral) and observed with SEM to
investigate the number of particles of spheroidal cementite per area of 1 mm2 for each
of a region from a surface to a position at 1/2 radius and a central part. That is, for the
region from the surface to a position at 112 radius, metal structure of 3 locations
including a position at 1 mm from the surface, an R/4 position, and an R/2 position was
observed with SEM at a magnification of 5000 times in 4 fields of view at an interval of
90° in the circumferential direction for each location, which amounts to a total of 12
fields of view; and using the picked up images, the major diameter L and the minor
diameter W of each cementite particle were measured individually by means of image
analysis software to count the number of particles of cementite in which L/W was not
more than 2.0, that is, spheroidal cementite, and finally calculate the number of particles
(llmm2) of spheroidal cementite per area of 1 mm2. Similarly, on the central part,
metal structure observation was made at in 2 locations including the 3R/4 position and
the center position with SEM at a magnification of 5000 times in 4 fields of view at an
interval of 90° in the circumferential direction for the 3R/4 position, and .1 field of view
for the center position, which amounts to a total of 5 fields of view; and using the
picked up images, the number of particles of spheroidal cementite per area of 1 mm2
was calculated with image analysis software.
[0120]
On the other hand, for a cross-section including the center line and parallel to
the rolling direction, electropolishing was further performed after mirror polishing, and
observation was made with an electron beam backscatter pattern method (hereafter
referred to as "EBSD").
[0121]
To be specific, for the microstructure of a region from a surface to a position at
1/2 radius, metal structure of 3 locations including a position at 1 mm from the surface,
an R/4 position and an R/2 position was observed with EBSD, and an average aspect
ratio of ferrite grains was determined by measuring the orientation of ferrite and
30
performing image analysis supposing that orientation difference of not less than 15°
indicate a grain boundary.
[0122]
Regarding tensile characteristic, a No. 14A specimen (in which, diameter of
parallel part: 4 mm) defined in JIS Z 2241 (2011) was taken such that the R/4 position
of each steel bar having a diameter of 34 mm coincided with the center axis of the
specimen, and a tensile test was conducted at room temperature with the gage length
being 20 mm to determine tensile strength (MPa).
[0123]
Regarding impact characteristic, a V-notch Charpy impact test specimen
already described was taken such that the notch was oriented toward the surface as
schematically shown in Figure 1 and the R/4 position of each steel bar having a
diameter of 34 mm exactly corresponded to the notch bottom position, and a Charpy
impact test was conducted at 25°C to determine impact values (J/cm2).
[0124]
Regarding machinability, after each steel bar having a diameter of 34 mm was
cut into a length of 1 70 mm, cutting resistance was evaluated by measuring torque when
a deep hole machining was performed up to a depth of 150 mm in the rolling direction
with reference to the center of the cross-section perpendicular to the rolling direction at
the following conditions by using a gun drill having a diameter of 8.0 mm.
- Revolution speed: 2300 rpm
- Feed: 0.05 mm/rev, and
- Oil supplying pressure: 5 MPa.
[0125]
Note that the target ofbase metal toughness was set as that the impact value be
not less than 120 J/cm2
• Moreover, the target of machinability was set as that the
above described torque be not more than 300 N ·em.
[0126]
Table 3 shows the results of each investigation described above. Note that
"0" mark in the "Evaluation" column of Table 3 indicates that the targets of impact
31
characteristic and machinability were both satisfied, and on the other hand, "x" mark
indicates that at least one of the targets was not achieved.
[0127]
[Table 3]
32
co
co
,.--,
-0 N
...0...0...
Table 3
Microstructure in a region extending from the surface to R/2 position Microstructure of central part Mechanical properties Machinability Test Steel Transverse section -- Transverse section Tensile V-notch Charpy impact Torque when performing Evalu-,
No. Phase Average grain Area Number of Average Phase Area Number of strength value deep hole machining ation I diameter ofF fraction of particles ofSC aspect ratio of fraction of particles of SC (lun) LP(%) (/mm2) F LP(%) (/mm2) (MPa) (J/cm2) with gun drill (N ·em)
1 A F+LP+C 5. 3 8.2 9. 5x 10 5 4.0 F+LP+C 34.3 LOx 105 780 200 270 01
2 8 F+LP+C 7.2 12.3 8. ox 10 5 4_4 F+LP+C 40.1 5. 0 X 104 770 205 255 0
3 c F+LP+C 3.3 5. 6 8. ox 105 4.5 F+LP+C 27.5 5. Ox 104 820 - 175 245 0
4 D F+LP+C 3. 7 6. 6 8.5x105 4.8 F+LP+C 31.2 3.0x104 790 235 265 0
5 E F+LP+C 4. 1 8. 1 7.5X105 4. 0 F+LP+C 42.6 4. 0 X 104 800 210 255 0
6 F F+LP+C 3.9 5. 9 B.Ox106 4. 2 F+LP+C 28.2 1.0x104 840 130 280 0
7 G F+LP+C 2.9 5. 3 9. Ox 106 4. 5 F+LP+C 34.3 1.0x105 740 225 240 0
8 H F+LP+C 7. 9 10.4 6. 5 X 105 5.5 F+LP+C 48.2 1. 0 X 104 845 145 285 0
9 I F+LP+C 6.4 7. 7 7.5xt05 4. 1 F+LP+C 37.9 1.0x1Q5 770 210 280 0'
1 0 J F+LP+C 3. 6 7. 5 9. 5x 105 4.& F+LP+C 34.3 5.0x104 760 225 245 0' 1 1 K F+LP+C 2.8 4.4 1.0x106 4.5 F+LP+C 42.9 7.0x104 840 145 265 0 I F+LP+C 1.9 5.3 1.0x1Q6 5. 0 F+LP+C 33.3 1. Ox 105 840 180 270 1 2 L 0.I
1 3 M F+LP+C 2.2 4.2 9.0x105 5.0 F+LP+C 36. 7 1.0x104 850 175 270 0
1 4 N F+LP+C 4. 2 5.1 7.5x10 5 4. 7 F+LP+C 38.3 1.0x104 780 230 245 0 , 5 0 F+LP+C 7. 3 5. 1 8. 0 X 106 5. 1 F+LP+C 34.4 8.0x104 820 155 285 0
1 6 p F+LP+C 3.4 4.2 8.0x105 5. 2 F+LP+C 48.3 5. 0 X 104 790 210 230 0 , 7 Q F+LP+C 3. 3 4.0 9.5xl05 4.3 F+LP+C 32.6 1. 0 X 104 835 150 290 0
1 8 *R F+LP+C 5. 1 6.2 8.0x106 4. 1 F+LP+C 51.5 1.5x 105 800 # 100 290 X'
, 9 *S F+LP+C 2.1 5. 1 1.0x106 4. 8 F+LP+C 57.3 1.5x 105 820 180 # 360 X
20 *T F+LP+C 2.'4 3.3 8.5x105 5. 0 F+LP+C 37.3 1.5x105 830 195 # 355 X
2.1 *U F+LP+C 1.9 3. 1 9.0x10 5 5. 0 F+LP+C 31.3 2..oxtos 700 # 95 240 X
22 *V F+LP+C 2.2. 4. 3 8. Ox 105 4.5 F+LP+C 29.2 5.0x104 830 # 110 # 42.0 X
23 *W F+LP+C 3. 3 4. 8 8. 0x1os 4. 0 F+LP+C 34.9 l.Ox10 6 795 210 # 450 X
24 E F+LP+C * 13.3 15.3 6.5x10 5 4.3 F+LP+C 44.0 3.0x104 720 # 110 250 X
25 E F+LP+C * 11.5 * 35.5 * 3. Ox 10 5 * 2.3 F+LP+C 50.6 2.0x104 740 # 90 255 X
2.6 E F+LP+C * 10.3 7.4 5.5x106 5. 1 F+LP+C * 12.3 *7.5x105 780 # 105 # 450 X
27 E F+LP+C 7.5 9. 9 7.0x105 * 1. 5 F+LP+C 30.0 5.0x104 760 # 110 265 X
28 E F+LP+C 6.2 10.2 6. 5x 10 5 4.0 F+LP+G * 11.5 * 4. 5 X 105 800 225 # 325 X
29 J F+LP+C * 17.9 * 40.3 * 5.0x10 4 * 1. 5 . F+LP+C 49.2 1.0x104 800 # 75 245 X
30 M F+LP+G *11.2 3. 2 8.5x105 6. 6 F+LP+C * 5. 3 * 7.5x105 815 # 100 # 490 X
3 1 p F+LP+C 5.4 8. 7 5. 0 X 105 * 1.4 F+LP+C 43. 1 5.0x104 760 # 105 225 X
In Microstructure columns. 'transverse section' refers to a cross-section perpendicular to rolling direction, and 'vertical section' refers to a cross-section including the center line and parallel to the rolling direction. Also 'F' inlfJC31.es
ferrite, 'LP' lamellar peariite, 'C' cementite, and 'SC' spheroidal cementite.
'Central part' refers to an area located within a distance up to 1/4 radius from the center.
"' mark indicates deviation from the conditions defined in the present invention. '#' mark indicates that its target is unreached.
----
Table 3 reveals that in the case of steel bars of Test Nos. 1 to 17 which satisfied
the conditions of chemical composition and microstructure defined in the present
invention, their evaluations were "0" indicating that they achieved targeted
characteristics (excellent base metal toughness of an impact value of not less than 120
J/cm2 at a test temperature of 25°C in a Charpy impact test using a V-notch Charpy
impact test specimen, and excellent machinability of a torque of not more than 300
N·cm when performing deep hole machining with a gun drill) without being subjected
to thermal refining treatment.
[0129]
In contrast to this, in the case of steel bars of Test Nos. 18 to 31 which deviated
from at least one of the conditions of the chemical composition and the microstructure
defined in the present invention, evaluations were "x" clearly indicating that the targeted
characteristics were not achieved, and omission of thermal refining treatment was not
possible.
[0130]
That is, in the case of Test No. 18, C content of Steel R used was as high as
0.58%, exceeding the value defined in the present invention. For this reason, the
V-notch Charpy impact value was as low as 100 J/cm2•
[0131]
In the case of Test No. 19, Si content of Steel S used was as high as 1.21 %,
exceeding the value defined in the present invention. For this reason, the torque when
performing deep hole machining with a gun drill was as high as 360 N·cm.
[0132]
In the case of Test No. 20, Mn content of Steel T used was as high as 2.20%,
exceeding the value defined in the present invention. For this reason, the torque when
performing deep hole machining with a gun drill was as high as 355 N·cm.
[0133]
In the case of Test No. 21, P content of Steel U used was as high as 0.052%,
exceeding the value defined in the present invention. For this reason, the V-notch
Charpy impact value was as low as 95 J/cm2.
34
[0134]
In the case of Test No. 22, S content of Steel V used was as low as 0.003%,
falling below the value defined in the present invention. For this reason, the V-notch
Charpy impact value was as low as 110 J/cm2, and the torque when deep hole
machining was performed with a gun drill was as high as 420 N·cm.
[0135]
In the case of Test No. 23, Cr content of Steel W used was as high as 2.18%,
exceeding the value defined in the preset;It invention. For this reason, the torque when
performing deep hole machining with a gun drill was as high as 450 N·cm.
[0136]
In the cases of Test Nos. 24 to 28, although the chemical composition of Steel
E used satisfied the conditions defined in the present invention, the microstructure
deviated from the range defined in the present invention. For this reason, as least one
of impact characteristic and machinability did not reach its target.
[0137]
To be specific, in the case of Test No. 24, the average grain diameter of ferrite
in a region from the surface to a position at 1/2 radius in a cross-section perpendicular
to the rolling direction was 13.3 J.I.IIl, deviating from the range defined in the present
invention. For this reason, the V-notch Charpy impact value was as low as 110 J/cm2
•
[0138]
In the case of Test No. 25, the average grain diameter of ferrite, the area
fraction of lamellar pearlite, and the number of particles of spheroidal cementite in a
region from the surface to a position at 1 /2 radius in a cross-section perpendicular to the
rolling direction, and the average aspect ratio of ferrite grains in a region from the
surface to a position at 112 radius in a cross-section including the center line and parallel
to the rolling direction were 11.5 J.I.IIl, 35.5%, 3.0x105/mm2
, and 2.3, respectively,
deviating from the ranges defined in the present invention. For this reason, the
V-notch Charpy impact value was as low as 90 J/cm2•
[0139]
In the case of Test No. 26, in a cross-section perpendicular to the rolling
35
direction, the average grain diameter of ferrite in a region from the surface to a position
at 1/2 radius, and the area fraction of lamellar pearlite and the number of particles of
spheroidal cementite in a central part were 10.3 J.I.IIl, 12.3%, and 7.5x105/mm2,
respectively, deviating from the ranges defined in the present invention. For this
reason, the V-notch Charpy impact value was as low as 105 J/cm2, and the torque when
performing deep hole machining with a gun drill was as high as 450 N·cm.
[0140]
In the case of Test No. 27, the average aspect ratio of ferrite grains in a region
from the surface to a position at 1/2 radius in a cross-section including the center line
and parallel to the rolling direction was 1.5, deviating from the range defined in the
present invention. For this reason, the V-notch Charpy impact value was as low as 110
J/cm2.
[0141]
In the case of Test No. 28, in a cross-section perpendicular to the rolling
direction, the area fraction of lamellar pearlite and the number of particles of spheroidal
cementite in a central part were 11.5% and 4.5x105/mm2
, respectively, deviating from
the ranges defined in the present invention. For this reason, the torque when
performing deep hole machining with a gun drill was as high as 325 N·cm.
[0142]
In the cases of Test Nos. 29 to 31, although the chemical compositions of
Steels J, M, and P used satisfied the conditions defined in the present invention, the
microstructures deviated from the range defined in the present invention. For this
reason, one or more of impact characteristic and machinability did not reach its target.
[0143]
To be specific, in the case of Test No. 29, the average grain diameter of ferrite,
the area fraction of lamellar pearlite, and the number of particles of spheroidal cementite
in a region from the surface to a position at 1/2 radius in a cross-section perpendicular
to the rolling direction, and the average aspect ratio of ferrite grains in a region from the
surface to a position at 1/2 radius in a cross-section including the center line and parallel
to the rolling direction were 17.9 J..lm, 40.3%, 5.0x104/mm2, and 1.5, respectively,
36
deviating from the ranges defined in the present invention. For this reason, the
V-notch Charpy impact value was as low as 75 J/cm2•
[0144]
In the case of Test No. 30, the average grain diameter of ferrite in a region from
the surface to a position at 1/2 radius, and the area fraction of lamellar pearlite and the
number of particles of spheroidal cementite in a central part in a cross-section
perpendicular to the rolling direction were 11.2 /-lm, 5.3%, and 7.5x 1 05/mm2,
respectively, deviating from the ranges defined in the present invention. For this
reason, the V-notch Charpy impact value was as low as 100 J/cm2, and the torque when
performing deep hole machining with a gun drill was as high as 490 N·cm.
[0145]
In the case of Test No. 31, the average aspect ratio of ferrite grains in a region
from the surface to a position at 112 radius in a cross-section including the center line
and parallel to the rolling direction was 1.4, deviating from the range defined in the
present invention. For this reason, the V-notch Charpy impact value was as low as 105
J/cm2• Note that while in this Test No., rolling in a range of 650 to 810°C was
conducted in Rough train and Finish train, and the cumulative reduction of area in the
range of 650 to 810°C was calculated as [(reduction of area in Rough train) + (100 -
cumulative reduction of area in Rough train and Intermediate train) x reduction of area
in Finish train/100]. That is, the cumulative reduction of area in a range of 650 to
810°C was given as [89.0 + (100- 92.3) x 53.8/100] = 93.1%.
[0146]
(Example 2)
By using steel bars, each of which had a diameter of 34 mm, of Test Nos. 5, 10,
13, 16, 18, 25, 29, and 31 obtained in Example 1, a specimen simulating a rack bar was
fabricated.
[0147]
First, a steel bar having a diameter of 34 mm was subjected to shotpeening to
remove surface scale, and thereafter was drawn into a diameter of 31 mm with lubricant
oil applied to the surface thereof.
37
[0148]
Next, the above described drawn material was processed into a specimen
simulating a steering rack bar shown in Figure 2.
[0149]
Further, induction quenching was performed by widely adjusting the condition
of induction quenching such that the depth of the hardened layer in an area
corresponding to the tooth bottom of the rack bar (a depth from the surface, at which
Vickers hardness is 450) be 1 mm. Thereafter, for the purpose of preventing cracking
after induction quenching, tempering treatment was conducted at 180°C for 2 hours.
[0150]
Next, using the specimen which had been subjected to the above described
induction quenching and thereafter to tempering, 3-point bending test was performed at
an inter-fulcrum distance of 180 mm and at a push-in speed of 1.0 rnrnlmin as shown in
Figure 3, and a "load - stroke (push-in distance) curve" was acquired to determine
"crack generation load" as a maximum load, that is, the load when a crack occurred, and
thereby load showed a change.
[0151]
Next, the specimen after the 3-point bending test was forced to rupture, and
thereafter outward appearance of the ruptured surface was photographed, and the area
fraction of the crack that propagated during the bending test was determined with
respect to the total cross-section by image analysis processing to evaluate crack
propagation· resistance. Note that the target of damage prevention characteristic was
set as that the area fraction of the crack that propagated during the above described
bending test be not more than 30%.
[0152]
Table 4 shows the results of each investigation described above. Note that
"0" mark in the "Evaluation" column of Table 4 indicates that the area fraction of the
crack that propagated during the bending test was not more than 30%, thus satisfying its
target, and on the other hand, "x" mark indicates that the target was not satisfied.
[0153]
38
[Table 4]
Table 4
Test Test No. of Crack Area fraction
No. Steel steel bar generation of crack that Total
produced in load propagated evaluation
Example 1 (N) (%)
3 2 E 5 60 25 0
3 3 J 1 0 55 25 0
34 M 1 3 55 25 0
3 5 p 1 6 55 20 0
3 6 *R * 1 8 60 # 85 X
3 7 E * 2 5 50 # 65 X
38 J * 29 55 # 70 X
3 9 p * 3 1 50 # 80 X
••• mark indicates deviation from the conditions defined in the present invention.
"#" mark indicates that its target is unreached.
[0154]
Table 4 reveals that in the case of steel bars of Test Nos. 32 to 35 which used
steel bars of Test Nos. 5, 10, 13, and 16 that satisfied the conditions of chemical
composition and microstructure defined in the present invention, their evaluations were
"0" indicating that they had excellent characteristic, that is, the area fraction of the
crack that propagated in the 3-point bending test was not more than 30%, without being
subjected to thermal refining treatment.
[0155]
In contrast to this, in the case of Test No. 36 which used the steel bar of Test
No. 18, since its V-notch Charpy impact value was as low as 100 J/cm2 as shown in
Table 3, the area fraction of the crack that propagated during the 3-point bending test
was as large as 85%, indicating poor damage prevention characteristic.
[0156]
Similarly, in the case of Test No. 37 which used the steel bar of Test No. 25,
39
since its V-notch Charpy impact value was as low as 90 J/cm2 as shown in Table 3, the
area fraction of the crack that propagated during the 3-point bending test was as large as
65%, indicating poor damage prevention characteristic.
[0157]
Also in the case of Test No. 38 which used the steel bar of Test No. 29, since its
V-notch Charpy impact value was as low as 75 J/cm2 as shown in Table 3, the area
fraction of the crack that propagated during the 3-point bending test was as large as 70%,
indicating poor damage prevention characteristic.
[0158]
Also in the case of Test No. 39 which used the steel bar ofTest No. 31, since its
V-notch Charpy impact value was as low as 105 J/cm2 as shown in Table 3, the area
fraction of the crack that propagated during the 3-point bending test was as large as 80%,
indicating poor damage prevention characteristic.
INDUSTRIAL APPLICABILITY
[0159]
Since the rolled round steel material for a steering rack bar of the present
invention has high base metal toughness of an impact value of not less than 120 J I cm2 at
a test temperature of 25° C in a Charpy impact test performed by using a V notch
Charpy impact test specimen, and further exhibits excellent machinability for machining
a deep hole in a central part thereof with a gun drill even without necessarily needing
expensive V to be contained and further in a state of rolled round steel material . even
without being subjected to thermal refining treatment, it is suitable for use as the
starting material for a steering rack bar.
[0160]
Further, a steering rack bar of the present invention can be obtained by using
the above described rolled round steel material for a steering rack bar in a non-thermally
refined state.

We claim:
1. A rolled round steel material for a steering rack bar, comprising: a chemical
composition consisting of, in mass%,
C: 0.38 to 0.55%,
Si: not more than 1.0%,
Mn: 0.20 to 2.0%,
S: 0.005 to 0.10%,
Cr: 0.01 to 2.0%,
Al: 0.003 to 0.10%,
N: 0.003 to 0.03%,
Cu:O to 1.0%,
Ni: 0 to 3.0%,
Mo: 0 to 0.50%,
Ti: 0 to 0.10%,
Nb: 0 to 0.10%,
V: 0 to 0.30%,
Ca: 0 to 0.005%, and
Pb: 0 to 0.30%,
with the balance being Fe and impurities, and
P being not more than 0.030% in the impurities; and
a microstructure consisting of ferrite, lamellar pearlite, and cementite, wherein
in a cross-section perpendicular to a rolling direction:
in a region from a surface to a position at 1/2 radius,
an average grain diameter of the ferrite is not more than 10 J..I.IIl,
an area fraction of the lamellar pearlite is less than 20%, and
a number of particles of spheroidal cementite among the cementite is not
less than 4x105/mm2; and
in a central part,
an area fraction of the lamellar pearlite is not less than 20%, and
41
a number of particles of spheroidal cementite among the cementite is less
than 4x 105 /mm2, and wherein
in a cross-section including a center line of the round steel material and parallel to the
rolling direction:
in a region from a surface to a position at 1/2 radius,
an average aspect ratio of the ferrite grains is not less than 3.
2. The rolled round steel material for a steering rack bar according to claim 1,
containing one or more elements selected from, in mass%, Cu: 0.10 to 1.0%, Ni: 0.10 to
3.0%, and Mo: 0.10 to 0.50%.
3. The rolled round steel material for a steering rack bar according to claim 1 or 2,
containing one or more elements selected from, -in mass%, Ti: 0.010 to 0.10%, Nb:
0.010 to 0.10%, and V: 0.010 to 0.30%.
4. The rolled round steel material for a steering rack bar according to any of
claims 1 to 3, containing one or more elements selected from, in mass%, Ca: 0.0005 to
0.005%, and Ph: 0.05 to 0.30%.
5. A steering rack bar, fabricated by using any of the rolled round steel materials
for a steering rack bar according to any of claims 1 to 4 in a non-thermally refined state.