JP2001073499A - Structure and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To joint hollow shapes well from the one-side faces without anxiety about the dimensional accuracy of the hollow shapes. SOLUTION: Projecting pieces 22b of face plates of hollow shapes 10, 20 are jointed from above by friction rotation jointing. A connecting member 30 is then placed on a seat part, and friction rotation jointing is carried out from above. The seat part is located at the intersection point of a face plate 11 (21) and a rib for connecting two face plates 11, 12 (21, 22). The connecting member 30 and the seat part and jointed not by butt-jointing but by lap jointing. This permits easy jointing even with the manufacturing error and arrangement error of the hollow shapes 10, 20.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a hollow structural member and a method for manufacturing the same. For example, it is suitable for manufacturing a structure using a hollow extruded member made of an aluminum alloy used for a railway vehicle, a building, and the like.

[0002]

2. Description of the Related Art In a friction stir welding method, a round bar (referred to as a rotary tool) inserted in a joint is moved along a joining line while rotating, so that the joint is heated, softened, plastically fluidized, and solid-phased. It is a joining method. The rotary tool has a small diameter portion inserted into the joint and a large diameter portion located outside. The small diameter part and the large diameter part are coaxial. The boundary between the small diameter portion and the large diameter portion is slightly inserted into the joint. This is disclosed in JP-A-9-3091.
No. 64 (EP0797043A2). FIG. 9 of this document shows that the joining of two surfaces of a hollow extruded profile is performed from one surface. Also shown is a joint for preventing deformation of the hollow profile.

[0003]

SUMMARY OF THE INVENTION The above-mentioned Japanese Patent Application Laid-Open No. 9-309 is disclosed.
As shown in FIG. 9 of Japanese Patent Publication No. 164 (EP0797043A2), a case where a hollow material is friction stir welded from one surface is considered. In this case, the accuracy of the interval between the plates 33, 33 on the upper surfaces of the two hollow members 31, 32 and the accuracy of the width of the joint 60 arranged in this portion are important. If the interval between the upper plates 33, 33 is smaller than the width of the joint 60, the joint 60 cannot be arranged. Conversely, the interval between 33 on the upper surface is
If the width is larger than 0, friction stir welding is difficult.
That is, it is important that the gap at the butted portion between the plate 33 and the joint 60 is small.

However, the hollow members 31, 32 and the joint 60
Large gaps are likely to occur in the butted portion due to manufacturing tolerances in the extrusion process. This is remarkable when a large number of hollow sections are joined side by side, as in the case of joining the bodies of railway vehicles. An object of the present invention is to enable good joining of a hollow profile from one surface, regardless of the dimensional accuracy of the hollow profile or the like.

[0005]

SUMMARY OF THE INVENTION The above object is achieved by connecting two face plates with a plurality of ribs, and the end of one face plate protrudes from the end of the other face plate. A shape member is prepared, the protruding face plates are joined to each other by friction stir welding from the other face plate side, and then, a connection portion between one end of the other face plate of the one hollow shape member and the rib The connection between the end of the other face plate and the rib of the other hollow profile overlaps each end of one connecting material, and the one hollow profile, the connecting material and one end The joining is performed by friction stir welding of the overlapped portion from the outside of the hollow profile, and the position of the friction stir welding is an inner position having a portion that is not friction stir welded to one end of the connection material, and The joining of the hollow shape member and the other end of the connection member is performed by joining the overlapped portion to the inside. The friction stir welding is performed from the outside of the shape member, or the other end of the connection member and the other face plate of the hollow shape member are arc welded, and the position of the friction stir welding is set at the other end of the connection material. At the inner position having a portion that is not friction stir welded.

[0006]

1 to 4 show an embodiment of the present invention.
This will be described below. In the following description, part numbers not shown in FIG. 1 may be used. In that case, the part number obtained by subtracting 10 from the part number corresponds to the part with the right half part number. 1 is an enlarged view of a main part of FIG. 2, and FIG.
3 is a longitudinal sectional view of a main part of the side structure shown in FIG.

The vehicle body 200 has a side structure 20 forming a side surface.
1, a roof structure 202 constituting a roof, an underframe 203 constituting a floor, and a wife structure 204 constituting an end in a longitudinal direction. The side structure 201, the roof structure 202, and the underframe 203 are each formed by joining a plurality of extruded members. The longitudinal direction of the extruded profile is set to the longitudinal direction of the vehicle body. The extruded profile is a hollow profile made of an aluminum alloy. The configuration and joining method of the hollow members 10 and 20 constituting the side structure 201 will be described. The same applies to other parts and other structures.

The hollow profiles 10, 20 are composed of two face plates 11, 1,
A plurality of ribs 13 arranged in a truss shape with 2, 21, 22;
23. The two face plates 11, 12 (21, 22) are substantially parallel. The pitch of the truss by the ribs 13 and 23 is the same. Truss: ribs 13, 23, face plate 1
1, 12, 21, and 22 are constituted by the center line of the plate thickness. The vertices are on the face plates 11, 12, 21, 22 side. Rails 19 and 29 for mounting equipment are integrally provided near the top of the truss inside the vehicle. The rails 19 and 29 are composed of two L-shaped members. The rails serve as seats for equipment such as interior boards and chairs.

The end portions of the face plates 12 and 22 located on the outer surface side of the vehicle body project toward the adjacent hollow members 20 and 10 than the end portions of the face plates 11 and 21 inside the vehicle. The protruding face plates are called 12b and 22b. The ends of the face plates 12b and 22b are abutted against each other to perform friction stir welding. The butting portions are butted so that the gap is small. Face plate 12
The plate thickness of b and 22b is larger than the plate thickness of the face plates 12 and 22 in the other portions.

The hollow members 10, 20 rest on a bed 40 with the face plates 12, 22 facing downward. The side of the face plates 11 and 21 faces upward. The rotary tool 250 is inserted into the joint from above to perform friction stir welding. It can be said that friction stir welding is performed from the inside of the car. At the ends of the face plates 12b and 22b, there are convex portions 16 and 26 protruding toward the vehicle inside (that is, the face plates 11 and 21 side). The width and height of the projections 16 and 26 are substantially the same.

An end of the face plate 11 on the inside of the vehicle and an end of the face plate 21 are joined via a connecting member 30. Connection material 3
The zero end rests (overlaps) on a seat 27 (17) provided at the top of the truss. Seat 27 (17) is rib 2
It is at the intersection of 3A (13A) and rib 23B (13B). The intersection is located at the center of the width of the seat 27 (17). That is, the vertex of the end truss is located at the center of the width of the seat 27 (17). The width of the seat 27 (17) is the same as the width of the projection 35 of the connection member 30. The seat 27 (17) is recessed from the outer surface of the face plate 21 (11). The seat 27 (17) is open to the outside in the thickness direction of the hollow profile and to the end in the width direction. Face plate 2
The end 27b (17b) of 1 (11) is inclined as a groove for arc welding with the connecting member 30.

The connecting members 30 are arranged so that the surfaces of the face plates 11 and 21 are continuous. For this reason, the seat 27 (17) is recessed by the thickness of the face plate 21 (11) with respect to the outer surface of the face plate 21 (11).
The center of the connecting member 30 excluding the both ends 35 is a plate 31 whose thickness is substantially the same as the thickness of the face plate 21 (11).

At both ends of the connecting member 30, there are convex portions 35 projecting upward. There is a V-shaped groove 36 on the upper surface of the projection. The groove 36 is located at the center of the width of the projection 35. The width of the convex portion 35 is larger than the diameter of the large diameter portion 252 of the rotary tool 250. The groove 36 is an object for position detection for guiding the rotary tool 250. The groove 36 is detected by the laser sensor so that the axis of the rotary tool 250 coincides with the groove 36. On the extension of the groove 36, that is, on the axis of the rotary tool 250, the two ribs 1
There is an intersection of 3A (23A) and 13B (23B).

The overlapping surface of the connecting member 30 and the seats 17 and 27 is flat and has no undulation, and they are in contact with each other. The width of the connecting member 30 is smaller than the distance between the face plates 11 and 21 of the two hollow members 10 and 20. The connecting member 30 is an extruded member made of the same material as the hollow members 10 and 20. The length of the connecting member 30 is the same as the length of the hollow members 10 and 20. The distance P (the distance from the top of the truss at the end of the hollow profile 10 to the top of the truss at the end of the hollow profile 20) from the end of the face plate 11 to the end of the face plate 21 is the same as that of the truss at another position. It is the same as the pitch P. The truss of the hollow material is an isosceles triangle when the side of the face plates 11, 12, 21, and 22 is a vertex. However, the trusses at the ends of the hollow members 10, 20 are not isosceles triangles. Ribs 13 forming trusses at the ends of hollow profiles 10 and 20
The angle formed between A and 23A with respect to the vertical line is θ1. The angle formed by the ribs 13A and 23B constituting the end truss with respect to the vertical line is θ2. θ1 <θ2.

For this reason, the rib 13A (23A) is
2 (22). Rib 13A and face plate 1
2 and the connection between the rib 23A and the face plate 22 have a space for inserting the friction stir welding apparatus. Since the ribs 13A and 23A stand up (θ1 is smaller) than the ribs 13B and 23A, the thickness of the ribs 13A and 23A is larger than the thickness of the ribs 13B and 23A. Rib 13B,
The plate thickness of 23B is larger than the plate thickness of the other ribs 13. The connection between the ribs 13A, 13B, 13 and the face plates 11, 12, 21, 22 is arc-shaped. Further, the thickness of the connection portion is determined from the viewpoint of strength.

A method of manufacturing this structure will be described. The hollow members 10 and 20 are placed on a bed 240 and fixed. The butted portions at the ends of the face plates 12b and 22b are in contact with or close to each other. The projections 16 and 26 of the butted portions of the face plates 12 and 22 are temporarily fixed by arc welding from above. Temporary welding is intermittent. Face plates 12b, 22b
The upper surface of the bed 240 on which the butting portion is placed is flat. Near the butted portion of the face plates 12b and 22b, the rib 13
A, 23A, near the intersection of the face plates 12b, 22b, rib 1
The three persons near the intersection of 3B, 23B and face plates 12, 22 are on bed 240 at the same height.

In this state, the friction stir welding is performed by moving the rotary tool 250 of the friction stir welding apparatus along the welding line with the rotary tool 250 being inserted from above into the butted portion of the projections 16 and 26. The axis of the rotary tool 250 is in the vertical direction (the direction along the normal line of the joint). However, the axis is inclined in a known manner with respect to the traveling direction of the rotary tool 250.
The butting portion of the two convex portions 16 and 26 is detected by the sensor to determine the position of the gap between the butting portions, and the axis of the rotary tool 250 is positioned in this gap.

The rotary tool 250 has a large diameter portion 252 and a small diameter portion 251 at the end thereof. The tip of the small diameter portion 251 is located near the lower surfaces of the face plates 12b and 22b. Large diameter part 2
The lower end of 52 is provided at the tops of the projections 16, 26 and the face plates 12b, 22b.
Of the vehicle (surfaces on the face plates 11 and 21 side). The diameter of the large diameter portion 252 is smaller than the width formed by the two convex portions 16 and 26. The small diameter portion 251 is a screw.

By this friction stir welding, the face plate 12b,
The gap between the butting portions 22b is filled and joined. The outer surface side (outside of the vehicle) of the butted portion is flatly joined. There is no concave portion of the joining line on the outer surface side of the face plates 12b and 22b. The upper surface of the convex portions 16 and 26 is the large diameter portion 2 of the rotary tool 250.
52 makes it concave. There are unjoined parts on both sides of the recess.

Next, the connecting member 30 is placed on the seats 17 and 27 of the face plates 11 and 21. The end of the connection member 30 is in contact with the surface of the seat 27. Next, the ends of the connection members 30 are connected to the face plates 11 and 21.
Are temporarily fixed by arc welding. Temporary welding is intermittent.

Next, the connection member 30 and the seats 17 and 27 are joined using the friction stir welding apparatus used for friction stir welding of the butted portions of the face plates 12b and 22b. Rotary tool 250
Is moved along the joining line in a state where the connecting member 30 and the seat 27 are inserted from above into the overlapped portion, and friction stir welding is performed.

The width of the convex portion 35 is the large diameter portion 2 of the rotary tool 250.
52 is larger than the diameter. A groove 36 is provided at the center of the width of the protrusion 35. The rotation axis of the rotary tool 250 is aligned with the groove 36. For this reason, the position of the rotary tool 250 is an inner position having a portion that is not friction stir welded to the end of the connection member 30. The tip of the small diameter portion 251 of the rotary tool 250 is inserted deeply into the seats 17 and 27. Thereby, lap joining is performed. The lower end of the large diameter portion 252 is a non-convex connecting material 3
0 and the top of the convex portion 35.

The upper surface of the convex portion 35 is concave by the large diameter portion 252 of the rotary tool 250. There are unjoined parts on both sides of the recess. The sensor of the friction stir welding apparatus detects the groove 36 and moves the rotary tool 250 along the groove 36. For this reason, the positional relationship between the rotary tool 250 and the sensor when joining the butted portions of the face plates 12b and 22b can be used as it is. The relationship between the other rotary tools and the joints is as described above.

The axis of the rotary tool 250 has two ribs 13
A, 13B (23A, 23B) lies on a vertical line passing at or near the vertex of the truss. For eccentricity, the thickness of the ribs 13A, 13B (23A, 23B) is increased, the shape of the arc connecting the rib and the face plate, the thickness of the connection portion,
Corresponding to the thickness of 7, 27, etc. The joining of the connecting member 30 is performed by joining with the seat 17 and then with the seat 27.
If two rotating tools are used, both ends of the connecting member 30 can be joined at the same time.

According to this, the joining of the connecting members 30 is lap joining, not butt joining. For this reason, the connecting member 30 can be joined even if the gap between the two hollow profiles 10 and 20 changes due to the manufacturing tolerance of the two hollow profiles 10 and 20 and the tolerance of the interval between the arrangement of the two hollow profiles. is there. Particularly, when a large number of hollow members are arranged and joined at one time, an error increases. In this case, since it is lap joining, it can be easily joined. Further, the joining of both sides of the hollow profile can be performed from one side. For this reason, there is no need to invert the structure in which one surface is joined. Therefore, it can be manufactured at low cost and with high precision.

The outer surface of the joint between the face plates 12b and 22b can be flatly joined. The convex portions 16, 26, and 35 are located inside the structure or inside the vehicle, and are required to have a smooth surface (the outer surface side,
Outside). In addition, there is no concave portion formed by cutting with the rotary tool on the outside of the vehicle. For this reason, the cutting of the convex portion can be made unnecessary, and the vehicle body can be manufactured at low cost. Further, the insertion force at the time of joining the connecting members 30 is equal to the rotating tool 250.
Two ribs 13A, 13B (2
3A, 23B). Therefore, the rib 1
The bending of 3A, 13B (23A, 23B) can be suppressed. 13A and 13B (23A and 23B) can be made thinner and lighter. Of course, face plates 11, 2
The bending of 1 and 30 can also be suppressed. Ribs 13A, 13B
Since the beds 240 supporting (23A, 23B) are at the same height, bending of the face plates 12, 22 can also be prevented.

Considering the case where the structure is used after the joining, substantially all of the structure is constituted by the truss structure. The joint between the hollow members 10 and 20 also has a truss structure. Therefore, the out-of-plane bending rigidity is improved, and the weight can be reduced. Since the connecting members 30, the face plates 12b and 22b and the ribs 13A and 23A between the ribs 13A and 23A substantially constitute a truss, these portions are not particularly weak. However, the thickness should be considered.

Further, the inclination angle θ1 of the ribs 13A, 23A can be made larger than the inclination angle θ2 of the ribs 13B, 23B. According to this, the width of the connection member 30 becomes large, and it becomes necessary to increase the thickness of the connection member 30, and the weight becomes large. However, it can be used when a large opening is required for insertion of the friction stir welding apparatus. By making the inclination angles θ1 and θ2 of the rib the same, it is possible to form an isosceles triangle. According to this, the plate thickness of the ribs 13A and 13B (23A and 23B) can be made the same. The thickness of the ribs 13A and 23A is shown in FIG.
It could be thinner than However, if the size of the isosceles triangular truss is made the same as the size of the truss at other places, the width of the connecting member 30 becomes large.

However, the two ribs 13A and 13B (23
If the inclination angles θ1 and θ2 of A, 23B) are the inclination angles θ1 of FIG. 1, the truss at the end can be made a small isosceles triangle. The size of the base of the truss at this end is smaller than the size of the base of the truss at other places. According to this,
The distance from the intersection of the rib 13B (23B) and the face plate 12 (22) to the end of the hollow profile 10 (20) can be reduced. Therefore, the width of the connecting member 30 can be made similar to the width of the connecting member 30 in FIG.

The pitch of all trusses including the connecting member 30 is the same. Except for the end truss, the size of the truss is the same. For this reason, the design of the hollow profile can be standardized. Two ribs 13A, 13B (23A, 23B)
May be located on the outer surface side of the face plates 21 and 31. Also, the two ribs 13A, 13B (23A, 23
The rotary tool 250 may be inserted at an angle toward the middle of the angle formed by B). The axis in this case is directed to the top of the truss.

In the above embodiment, the joining of the connecting members 30 is performed by friction stir welding, but may be performed in combination with arc welding. Since the friction stir welding is lap welding, the joining strength is lower than that of butt welding. Therefore, the butted portions of the end portions of the connecting members 30 and the face plates 21 and 31 are arc-welded. The location of the arc welding is, for example, a region where the strength is low. Also, arc welding can be used for repair.

In the above embodiment, both ends of the connection member 30 are joined by friction stir welding, but one end may be joined by friction stir welding and the other end may be joined by arc welding. Since arc welding has a larger distortion, friction stir welding is performed first.

In the above embodiment, the face plates 11, 12, 21, 22
Are parallel, but it is possible to cope with a case where one face plate is inclined with respect to the other face plate. Rib 13
A, 13B (23A, 23B) in the thickness, face plate 1
The plate thickness on the sides 1 and 21 is made larger than that on the face plates 12 and 22.
The reason for increasing the thickness of the face plates 11 and 21 is that the temperature tends to be high during joining.

In the above embodiment, the face plate at the joint is horizontal. However, the joint can be similarly performed even when the normal of the face plate at the joint is inclined. This is likely to occur at the joining line at the end of the side structure 201. In this case, the axis of the rotating body is along the normal of the face plate.

The embodiment shown in FIG. 5 will be described. Hollow profile 10C
Is perpendicular to the face plates 11C and 12C (along the normal of the face plate). Face plate 11C and rib 1
At the connection portion with 3C, there is a seat 17C of a concave portion similar to the above. 17Cb is a protruding piece connected to the seat 17C, and
30 appears. The rotating tool 25 is set within the range of the thickness of the rib 13C.
There is a zero rotation axis and a groove 36. In this case, the insertion force during friction stir welding is supported by the rib. The center of the thickness of the rib 13C is located at the center of the width of the seat 17C including the protruding piece 17Cb. The width of the seat 17C including the protruding piece 17Cb is the same as the width of the projection 35. The rib at the end of the other hollow profile can be made in this way.

The technical scope of the present invention is not limited to the language described in each claim or the language described in the section for solving the problem, and is easily replaced by those skilled in the art. It extends to a range.

[0037]

According to the present invention, since lap joining is performed,
It can be easily joined regardless of the dimensional accuracy of the hollow profile.

[Brief description of the drawings]

FIG. 1 is a longitudinal sectional view of a main part of a joint according to an embodiment of the present invention.

FIG. 2 is a longitudinal sectional view of a joint according to an embodiment of the present invention.

FIG. 3 is a longitudinal sectional view of a pair of hollow profiles according to an embodiment of the present invention.

FIG. 4 is a perspective view of a vehicle body of a railway vehicle.

FIG. 5 is a longitudinal sectional view of a main part of another embodiment of the present invention.

[Explanation of symbols]

10, 10C, 20 Hollow profile 11, 11C, 12, 11b, 12C, 21, 22, 2,
2b face plate 13, 13A, 13B, 13C, 23, 23A, 23B
Rib 17, 17C, 27 Seat 30 Connection material 201 Side structure 202 Roof structure 203 Underframe 240 Bed 250 Rotary tool

 ────────────────────────────────────────────────── ─── Continuing on the front page (72) Inventor Masakuni Esumi 794, Higashi-Toyoi, Katsumatsu-shi, Yamaguchi Prefecture F-term in the Kasado Works of Hitachi, Ltd. EA00

Claims (1)

[Claims] 1. A method for preparing two hollow profiles, wherein two face plates are connected by a plurality of ribs, and an end of one face plate protrudes from an end of the other face plate. The face plates that have been joined to each other by friction stir welding from the other face plate side, Next, the connection portion between the end of the other face plate of one of the hollow profile and the rib, the other of the hollow profile Each end of one connecting member is overlapped on a connecting portion between the end of the other face plate and the rib, and the joining of the one hollow shape member, the connecting member and one end is performed by overlapping the overlapped portion. The friction stir welding is performed from the outside of the hollow member, and the position of the friction stir welding is an inner position having a portion that is not friction stir welded at one end of the connection member. The other end is joined by friction stir from the outside of the hollow section. Performing welding, or arc welding the other end of the connecting material and the other face plate of the hollow profile, the position of the friction stir welding, the portion that is not friction stir welding to the other end of the connecting material A structure having an inner position.