JP3717450B2 - Method for manufacturing curved surface structure and curved surface structure - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method of manufacturing a relatively large structure by joining a plurality of curved plates. For example, it is suitable for the production of a part having a three-dimensional curved surface, such as a leading part of a railway vehicle, such as a leading car, an aircraft, a hull, etc., because of improved fluid characteristics.
[0002]
[Prior art]
The leading part of the leading car of the railway vehicle has a three-dimensional curved surface from the viewpoint of air resistance and design. It also requires a fairly complex curved surface. There exists Unexamined-Japanese-Patent No. 2000-301365 as a manufacturing method of such a curved structure. In this method, the top part of the top car is divided into a plurality of parts, and these individual blocks are joined to form the top car. The block is configured by pressing a plate to produce a curved plate, and then cutting one surface of the curved plate to provide a grid-like rib.
[0003]
Japanese Patent Laid-Open No. 6-23451 shows a method for manufacturing a hollow panel. A member having a plurality of ribs is provided by an extruded shape, and a plate is placed on the ribs and welded to manufacture a hollow panel.
[0004]
As disclosed in JP-A-9-309164 (EP 0797043 A2), there is friction stir welding as a joining means. There is a feature that there is little joint deformation and dimensional change.
[0005]
[Problems to be solved by the invention]
In Japanese Patent Laid-Open No. 2000-301365, a curved plate is manufactured by pressing a plate, and then a block provided with ribs is manufactured by cutting one surface of the curved plate. However, since there is no face plate on one side of the rib, the required rib height is large in terms of structural strength. This is, for example, 25 to 30 mm in the case of the Shinkansen. If the height of the ribs is large, the material cost is large because the thickness of the material plate is large (the leading car on the Shinkansen requires about 35 to 40 mm). Further, when the plate thickness is large, it takes time to form the curved plate, and it takes time to cut the ribs. For this reason, processing costs are also high.
[0006]
An object of the present invention is to provide a relatively large curved surface structure such as a railway vehicle at low cost with high accuracy.
[0007]
[Means for Solving the Problems]
The above purpose is
Bend the plate into a curved shape,
Next, one side of the plate is cut out to form a first face plate connecting the plurality of ribs and the plurality of ribs,
Next, fixing a second face plate substantially parallel to the first face plate at the tips of the plurality of ribs;
Can be achieved.
[0008]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the case where the present invention is applied to the leading portion of the leading vehicle of a railway vehicle will be described with reference to FIGS. FIG. 1 is a view of the block 50 as seen from the inside of the vehicle. FIG. 3 shows a connecting portion between the blocks.
[0009]
The head portions S1, S2, and S3 of the vehicle body have a three-dimensional curved surface that is bent along the longitudinal direction and the width direction of the vehicle body. Part S3 has a driver's seat window C. The portion S3 often has a curved surface that protrudes further from the curved surface. For this reason, the portion S3 often has a complicated curved surface. Part S4 is a guest room part, and has entrances D1 and D2 and a window W. Since the outer surface of this part is linear along the longitudinal direction of the vehicle body, it has the conventional configuration. The leading car includes a frame 100 constituting the floor, a curved surface part S3 placed on the frame 100, a straight line part S4, and curved surface parts S2 and S3 installed at the tip of the curved surface part S3.
[0010]
Block 50 is applied to a relatively large curved surface portion (portion where the height of the vehicle body is high) S3. The curved surface portions S1 and S2 can be similarly manufactured. The curved surface portion S3 is configured by connecting a plurality of blocks 50 in the longitudinal direction and the width direction of the vehicle.
[0011]
The lower end of the portion S3 made up of the plurality of blocks 50 is placed on the frame 100 of the vehicle body. The same applies to the other portions S4.
[0012]
The block 50 includes a face plate 51 that forms the outer surface of the vehicle, a plurality of ribs 55 that protrude from the inner surface of the face plate 51, and an inner face plate 52 that is fixed to the end face of the tip of the rib 55. The rib 55 includes a plurality of vertical ribs along the vertical direction (vertical direction) and a plurality of horizontal ribs along the horizontal direction (horizontal direction). The ribs 55 are connected to each other in a lattice shape. The protruding margin of the rib 55 is the same. The tips of the ribs 55 are flat and substantially parallel to the face plate 51. Each block 50 has a rib 55 at its end. For this reason, if the face plate 51 of the block 50 is a quadrangle, the ribs 55 are provided along the four sides of the face plate 51. The face plate 52 is fixed to each rib 55 by an appropriate means. The fixed position is determined in consideration of strength and the like. The face plate 52 overlaps with the rib 55 at the outer peripheral end of the block 50 and is fixed to the rib 55. It overlaps with the inner rib 55 from the outer peripheral end of the face plate 52, and is fixed to the rib 55. The fixing means is, for example, welding.
[0013]
The block 50 is curved and the face plates 51 and 52 are curved. The outer peripheral edge of the block 50 (face plates 51 and 52) is generally a quadrangle. The corner where the four blocks 50 contact is chamfered.
[0014]
One block 50 and the other adjacent block 50 are joined at a rib 55 at the end. Welding W1 is performed from the outside of the vehicle. For this reason, a groove for welding is provided at the outer end of the rib 55 at the outer peripheral end. The ribs 55 are generally in contact with each other, but there may be a slight gap. From the inside of the vehicle, the inner face plates 52 and 52 and the ends of the ribs 55 and 55 are welded W2. Of course, a groove for welding may also be provided at the inner end of the rib 55. The outer weld W1 is continuous, but the inner weld W2 may be intermittent depending on the strength. The inner groove may be smaller than the outer groove. In this way, the load is transmitted by the face plate 51 on the vehicle exterior side.
[0015]
Thus, when the inner face plate 52 is viewed from the face plate 51 side, it can be said that the shapes and sizes of the outer peripheries of the double-sided plates 51 and 52 are substantially the same. However, it differs depending on the shape of the groove and the shape of the corner as described above. As a welding joint, for example, on the vehicle outer side, the face plate 51 of one block 50 is overlapped with the rib 55 at the end of the adjacent block 50, and the face plates 51 are butted together and joined. However, the inside of the vehicle may be simply butted and welded as described above. In this case, although it differs greatly, it can be said that it is substantially the same.
[0016]
A means for fixing the face plate 52 to the rib 55 will be described. The face plate 52 is fixed to the end faces of the plurality of ribs 55 by welding W31 and W32. The welds W31 and W32 are plug welds. For this reason, holes h31 and h32 are formed in advance in the welded portion of the face plate 52. The hole h31 (W31) is located at the intersection of the ribs 55. The hole h32 (W32) is at the position of the long rib 55 between the intersection of the ribs 55 and the intersection of the ribs 55. The hole h32 is a long hole. Thus, since the face plate 52 is intermittently welded to the highly rigid rib 55, a highly accurate block (curved surface structure) 50 can be obtained without causing deformation.
[0017]
The outer peripheral end of the face plate 52 is inside the end face of the rib 55 at the outer peripheral end of the face plate 51 . For this reason, when the blocks 50 and 50 are brought into contact with each other, a gap is generated between the end of the face plate 52 and the end of the adjacent face plate 52. This gap substantially becomes a groove for the weld W2.
[0018]
In FIG. 1, the face plate 52 is cut along the holes h <b> 31 and h <b> 32 so as to be shorter than the length of the block 50.
[0019]
For example, in the case of a Shinkansen car body, the thickness of the face plate 51 is 2.5 mm, and the height of the rib 55 is 15 to 20 mm. The thickness of this material is 25-30 mm. Further, the thickness of the face plate 52 is 2.5 mm. The material of the block 50 is an aluminum alloy.
[0020]
The manufacturing procedure of the block 50 will be described with reference to FIG . First, the material plate constituting the face plate 51 and the rib 55 is cut (step S100).
[0021]
Next, the plate made of this material is pressed into a curved plate. This pressing is performed by heating the plate to about 300 ° C. Next, in a state in which the curved plate is sandwiched between the press molds at a predetermined pressure, annealing is performed by holding at about 350 ° C. for about 1 hour (step S110).
[0022]
Next, with a 5-axis machining center or the like, the outer surface side of the curved plate (the outer surface side of the vehicle) is cut to the extent that the material surface can be removed to provide a reference surface (step S120).
[0023]
Next, the curved plate is reversed, the inner surface side (the inner surface side of the vehicle) of the curved plate is cut, and the rib 55 is formed. The protruding direction of the plurality of ribs 55 is substantially orthogonal to the face plate 51. Furthermore, processing is advanced and the inner surface of the face plate 51 is completed. For example, the rib 55 has a height of 15 mm, a thickness of 6 mm, and a pitch of 200 mm. The roundness at the base of the rib 55 and the face plate 51 is, for example, 5 mm (step S130).
[0024]
Next, the curved plate is inverted and the outer surface of the face plate 51 is cut and finished. The thickness of the face plate is, for example, 2.5 mm. Further, the thickness can be increased in the partial portion depending on the required strength condition. Next, in the same state, the outer periphery of the block is trimmed and cut to finish the end face of the outer peripheral rib 55. Further, a groove is provided (S140).
[0025]
A procedure for manufacturing the face plate 52 on the vehicle inner side will be described. First, the face plate 52 is cut into a predetermined size. The plate thickness is, for example, 2.5 mm, and is cut slightly larger than the size of the block 50 (S200).
[0026]
Next, the plate of the face plate 52 is pressed using the press die used in step S110 to make a curved plate. Since the face plate 51 and the rib 55 are similar in thickness to the material of the integral panel, a curved plate with a slight error in shape accuracy can be obtained even if the same die is used. Annealing is unnecessary (S210).
[0027]
Next, holes h31 and h32 are formed in the face plate 52. Further, the outer peripheral edge of the face plate 52 is trimmed to a predetermined size of the face plate 52 (S220).
[0028]
Next, the face plate 52 is welded W31 and W32 to the rib of the block obtained in step S140. As a result, the block 50 is obtained.
[0029]
Since the block configured in this way is manufactured mainly by machining, it has high accuracy and has a high rigidity because it has a face plate rib integrated structure. Since the curved inner plate press-molded with high accuracy is fixed to the rib, the rigidity can be increased. As a result, a lightweight and highly rigid highly accurate curved structure and block can be obtained.
[0030]
Since this size is limited by the mold and processing equipment, the practical maximum dimensions are approximately 2 m in width and 3 m in length.
[0031]
A vehicle body is manufactured using the block 50 thus obtained. This procedure will be described with reference to FIG .
[0032]
First, a plurality of blocks 50 are placed on the gantry (S300).
[0033]
Next, the blocks 50 are temporarily welded together. Temporary welding is performed at a plurality of appropriate positions on the inner and outer welding lines (S310).
[0034]
Next, the blocks 50 are welded W2 from the inside of the vehicle. This welding is, for example, intermittent welding with a welding length of 50 mm and an interval of 150 mm (S320).
[0035]
Next, the blocks 50 are welded W1 from the face plate 51 side (S330).
[0036]
Next, the weld bead on the outside of the vehicle is cut in the same plane as the face plate 51 (S340).
[0037]
Next, the structure thus configured is placed on the underframe of the vehicle body and welded to form the vehicle body (S350).
[0038]
The embodiment of FIG. 7 will be described. This is fixed by a bolt b instead of the weld W31. The position of the bolt b is the position of the intersection of the ribs 55 and 55. The face plate 52 is provided with a hole h41 and a screw hole t at the intersection of the rib 55. The weld W32 is as in the above embodiment. After the bolt b is tightened to position the face plate 52, arc welding W32 is performed. For this reason, the position plate 52 can be prevented from being displaced and lifted, and the block 50 with high accuracy can be obtained without causing deformation.
[0039]
In addition, you may fix with a pin instead of the volt | bolt b. Further, depending on the required strength, only the bolt b or the pin can be used except the weld W2.
[0040]
The embodiment of FIG. 8 will be described. In this structure, the face plate 52 is overlapped with the end face of the rib 51 and joined by friction stir welding F. According to this, since it couple | bonds without fuse | melting, the curved surface structure 50 with sufficient precision is obtained, without producing a deformation | transformation. The friction stir welding is performed from above the face plate 52 as shown in FIG.
[0041]
A hole v is generated at the end point of the friction stir welding. When the hole v remains unsatisfactory, the hole v is filled with the arc welding w31 from above.
[0042]
In the case of friction stir welding, a load for friction stir welding is applied to the rib 55. This load is large. Since the rib 55 stands upright on the face plate 51 and is friction stir welded from this upright direction, the rib 55 can be prevented from being deformed and friction stir welded.
[0043]
At the time of friction stir welding, the face plate 52 must be firmly fixed to the face plate 51 side. For this reason, the outer peripheral end of the face plate 52 is firmly fixed by being sandwiched between the ribs 55 at the outer peripheral end of the face plate 51 with metal fittings. In this state, first, friction stir welding F is performed along the rib 55 at the center. Thereafter, the friction stir welding F is performed along the outer peripheral end ribs 55 except for the metal fittings for the friction stir welding.
[0044]
Further, as in the embodiment of FIG. 1, a face plate 52 having holes h31 or holes h32 provided at necessary places is used, and the face plate 52 is temporarily fixed to the rib 55 by welding. Next, friction stir welding F is performed. The length of the hole h32 may be short.
[0045]
Further, if a hole is further formed in the hole at the end point of the friction stir welding and the holes are connected with a bolt or a pin, the hole at the end point of the friction stir welding is filled to be firmly bonded. Further, when it is desired to provide this bolt or pin at another position (for example, at the intersection of ribs), a hole is made after the friction stir welding.
[0046]
The technical scope of the present invention is not limited to the wording described in each claim of the claims or the wording described in the means for solving the problem, and includes a range that can be easily replaced by a person skilled in the art. It extends.
[0047]
【The invention's effect】
According to the present invention, since another face plate is fixed inside the face plate rib-integrated panel, a lightweight and highly rigid high-precision block can be manufactured at low cost.
[Brief description of the drawings]
FIG. 1 is a perspective view of a block according to an embodiment of the present invention.
2 is a partially cutaway perspective view of a front portion of a vehicle body using the block of FIG.
3 is a cross-sectional view taken along the line 3-3 in FIG.
4 is a side view of the vehicle body of FIG. 3. FIG.
FIG. 5 is a flowchart illustrating a block manufacturing method.
FIG. 6 is a flowchart illustrating a method for manufacturing a large structure.
FIG. 7 is a perspective view of another embodiment of the present invention.
FIG. 8 is a perspective view of another embodiment of the present invention.
[Explanation of symbols]
50: Block, 51, 52: Face plate, 55: Rib, b: Bolt, F: Friction stir welding, w1, w2: Welding.

Claims (6)

Bending the material plate into a three-dimensional curved surface to produce a curved plate,
Next, one surface of the curved plate is cut out to form a first face plate and a plurality of ribs on the curved plate, and the plurality of ribs are connected to one surface of the first face plate. The plurality of ribs are formed in a lattice shape, the surface opposite to the ribs of the first face plate is formed in a three-dimensional curved surface, and the tips of the plurality of ribs are arranged at the first ends. Formed substantially parallel to the face plate of
Next, fixing a second face plate formed in a three-dimensional curved surface substantially parallel to the first face plate to the tips of the plurality of ribs formed in a lattice shape ,
A method of manufacturing a curved surface structure characterized by In the manufacturing method of the curved-surface structure of Claim 1,
Pressing the material plate with a pair of dies and bending it into a three-dimensional curved surface ,
Pressing the second face plate using the mold to form a three-dimensional curved surface ;
A method of manufacturing a curved surface structure characterized by A first face plate formed in a three-dimensional curved surface, and a second face plate formed in a three-dimensional curved surface substantially parallel to the first face plate ,
The first face plate is formed by cutting out grid-like ribs protruding in a direction substantially perpendicular from one surface thereof, and the tips of the ribs are substantially formed with respect to the first face plate. Is formed in parallel with
The second face plate is fixed to the tips of the grid-like ribs, and the fixing position of the second face plate to the ribs is an intersection of the grid-like ribs ,
Curved surface structure characterized by A first face plate formed in a three-dimensional curved surface, and a second face plate formed in a three-dimensional curved surface substantially parallel to the first face plate,
The first face plate is formed by cutting out grid-like ribs protruding in a direction substantially perpendicular from one surface thereof, and the tips of the ribs are substantially formed with respect to the first face plate. Is formed in parallel with
The second face plate is fixed to the tips of the grid-like ribs, and the fixing position of the second face plate to the ribs is a rib extending between the intersection points of the grid-like ribs. The tip ,
Curved surface structure characterized by The curved surface structure according to claim 4, wherein the fixing position of the second face plate to the rib is the intersection of the ribs and the tip of the rib extending between the intersections of the ribs ,
Curved surface structure characterized by The curved surface structure according to claim 3 or 4, wherein the rib is formed along an outer peripheral portion of the first face plate,
The second face plate is formed in such a size that an outer peripheral end of the second face plate coincides with a rib formed on an outer peripheral portion of the first face plate, and the outer peripheral end of the second face plate is Being fixed to the tip of the rib on the outer periphery of the first face plate ;
Curved surface structure characterized by

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