JP2004243379A

JP2004243379A - Hollow structure shaped material and method for manufacturing structure

Info

Publication number: JP2004243379A
Application number: JP2003036243A
Authority: JP
Inventors: Yoshikuni Kato; 慶訓加藤
Original assignee: Mitsubishi Heavy Industries Ltd
Current assignee: Mitsubishi Heavy Industries Ltd
Priority date: 2003-02-14
Filing date: 2003-02-14
Publication date: 2004-09-02
Anticipated expiration: 2023-02-14
Also published as: JP4326234B2

Abstract

<P>PROBLEM TO BE SOLVED: To provide a hollow structure shaped material in which the hollow structure shaped materials 40 each other can be joined by moving a friction stir joining tool 30 only from one side of the hollow structure shaped material 40, and moreover, which is suitable for joining by using a rotary tool 30 for bobbin type friction stir joining, and a method for manufacturing a structure using it. <P>SOLUTION: The hollow structure shaped material 40 is composed of two opposing plates 40a, 40b and a plurality of rib plates 40c which connect and support both plates. The tip of the two opposing plates 40a, 40b is extended further compared with the connection part with the rib plate 40c at the very end. And, the tip of one plate 40a of the two opposing plates 40a, 40b is shortened compared with that of the other plate 40b. The structure can be manufactured by performing the friction stir joining to the other plates 40b between each other of the two hollow structure shaped materials 40, and next, to a joint plate 41 and one plate 40a by using the bobbin tool 30. <P>COPYRIGHT: (C)2004,JPO&NCIPI

Description

【０００１】
【発明の属する技術分野】
摩擦攪拌接合用回転ツールを用いて、摩擦攪拌により接合可能な板からなるハニカム構造の中空構造型材同士を接合して構造物を製造する技術に関し、特に、ボビン型摩擦攪拌接合回転ツールを用いて接合するのに適した中空構造型材及びそれを用いた構造物の製造方法に関する。
【０００２】
【従来の技術】
従来から、鉄道車両構造として、車両の左右の側構体、床構体、屋根構体等を、長手方向に延在する長尺の中空構造型材を用い、該中空構造型材を長手方向にのみ接合するだけで、前記側構体、床構体、屋根構体等を構成するものが知られている（例えば、特許文献１参照）。
【０００３】
このような中空構造型材同士の接合に関し、図９で示すように、中空構造型材である中空パネル２０は、垂直リブ２０ｂから下面板２０ｃが延びた形をしている。そして、先ずこの下面板２０ｃを突合せて接合し、次いで、この突き出した下面板２０ｃの上部の空いたところに、継手板２１をはめ、この継手板２１の両端を上面板２０ａ接合する。こうすることにより中空パネル２０の上下面板を一方の側のみから接合できるものが知られている。
【０００４】
しかしながら、摩擦攪拌接合回転ツール１１として、接合する板に対して回転面を一方からのみ押し付けて摩擦攪拌接合するプローブ型を用いているため、面板に押し付ける力を支えるための架台（ベッド）等の支持部材１３が必要である（例えば、特許文献２参照）。
【０００５】
【特許文献１】
特開平２−２４６８６３号公報（第二頁、第１図）
【特許文献２】
特開平１１−３１４１８１号公報（段落００２７、図９）
【０００６】
【発明が解決しようとする課題】
ところで、このような従来技術によれば、中空構造型材を用いて車両などの構造物を摩擦攪拌接合によって製作する場合において、架台等の支持部材が必要であった。中空構造型材を水平な状態で並べて接合する場合には、架台等の支持部材を必要とするものの、架台等の構造や架台等への中空構造型材の設置も簡単であった。
【０００７】
しかし、屋根構体、側構体、床構体をサブユニットとして組み立てて完成した車体とするときには、最終工程で、各構体は立体的に配置されているから、垂直の状態で接合する箇所があり、垂直面を支持する支持部材を車体内部側に設置する必要も生じ、このような支持部材を各接合箇所に一々セットするのは面倒な作業であると共に過大な設備が必要となる。
【０００８】
本発明は上記事情に鑑みて成されたものであり、この問題に対し、摩擦攪拌接合ツールを中空構造型材の片側からのみ移動させて、中空構造型材同士を接合することができ、しかも、支持部材を設ける必要のないようにするため、接合する板を対向する２つの回転面に挟んで摩擦攪拌接合をするボビン型摩擦攪拌接合回転ツールを用いて接合するのに適した中空構造型材及びそれを用いた構造物の製造方法を提供することを目的とする。
【０００９】
【課題を解決するための手段】
本発明は、上記課題を解決するため、以下の手段を採用することとした。
請求項１に記載の発明は、対向する２つの板と前記両板を接続支持する複数のリブ板とからなる中空構造型材において、前記対向する２つの板は最も端のリブ板との接続部分よりも先端が延出しかつ前記対向する２つの板のうち一の板は他の板よりも先端が短いことを特徴としている。
【００１０】
この構成により、中空構造型材同士を接合して構造物を製造するときに、中空構造型材が一の板も他の板もリブ板との接続部分よりも延出している部分を有する構成であるため、その部分をボビン型摩擦攪拌接合用回転ツールの回転面間で挟むことができ、ボビン型摩擦攪拌接合用回転ツールを用いて中空構造型材同士を接合できる。このためプロープ型の摩擦攪拌回転ツールを用いる場合のように、回転ツールを押し付ける力に抗するための支持部材を必要としない。
【００１１】
また、一の板の先端同士の間を摩擦攪拌接合用回転ツールの移動空間とすることができるため、他の板同士を接合するに際して、他の板の外側から摩擦攪拌接合用回転ツールを用いる必要がなく、中空構造型材を反転させることなく、一の板の側からの作業ですむ。一の板同士は平板からなる継手板を介して接続するが、一の板と継手板との接合も一の板の側から作業でき、どちらの板の接合作業も一の板側からの作業となり、作業及びそれに必要な設備が簡単になる。
【００１２】
請求項２に記載の発明は、請求項１に記載の中空構造型材において、前記一の板の先端に、継手板と接続できるとともに、前記一の板の外表面側から前記継手板をはめて位置決め固定するための継手形状が形成されていることを特徴としている。
【００１３】
この構成により、中空構造型材同士を接合するときに、継手板を一の板同士の間にはめて、継手板を介して一の板同士を接続するが、継手板を一の板の外表面側からはめて、継手板を一の板に対して位置決め固定できるので、操作が簡単である。
【００１４】
請求項３に記載の発明は、請求項１に記載の中空構造型材において、前記継手形状として、前記一の板の先端側面が外表面側に段状となるよう形成されていることを特徴としている。
【００１５】
この構成により、中空構造型材同士を接合するときに、継手板を一の板同士の間にはめて、継手板を介して一の板同士を接続するが、一の板の先端側面の段状形状が外表面側でへこんでいるため、継手板を一の板の外側からはめやすく、簡単に位置決め固定できる。さらに、例えば、継手板にも段状を形成すると固定したときより安定性がある。
【００１６】
請求項４に記載の発明は、請求項１に記載の中空構造型材において、前記継手形状として、前記一の板の先端側面が前記一の板の内表面から外表面に向かって開いた傾斜面に形成されていることを特徴としている。
【００１７】
この構成により、中空構造型材同士を接合するときに、一の板の先端側面の傾斜面に合わさる傾斜面を側面にもつ継手板を介して一の板同士を接続すると、一の板の先端側面は一の板の内表面から外表面に向かって開いた傾斜となっているため、継手板を一の板の外側からはめやすく、簡単に位置決め固定でき、かつ、継手板材と一の板との接合部分が傾斜面同士であるため、隙間ができ難いので、摩擦攪拌接合したときに欠陥が生じ難い。
【００１８】
請求項５に記載の発明は、対向する２つの板と前記両板を接続支持する複数のリブ板とからなる中空構造型材同士を摩擦接合して構造物を製造する構造物製造方法において、前記対向する２つの板は最も端のそれぞれのリブ板との接続部分よりも先端が延出しかつ前記対向する２つの板のうち一の板は他の板よりも先端が短い前記中空構造型材となっていて、対向する回転面と前記回転面を繋ぐ回転軸とを先端に有するボビン型摩擦攪拌接合用回転ツールを一の板の先端同士の間隔からなる空間を移動させて他の板同士を摩擦攪拌により接合する工程と、次に、前記ボビン型摩擦攪拌接合用回転ツールを用いて前記継手板と前記一の板とを摩擦攪拌により接合する工程とからなることを特徴としている。
【００１９】
この構成によると、中空構造型材同士を接合して構造物を製造するときに、中空構造型材が一の板も他の板もリブ板との接続部分よりも延出している部分を有する構成であるため、その部分をボビン型摩擦攪拌接合用回転ツールの回転面間で挟むところにでき、ボビン型摩擦攪拌接合用回転ツールを用いて中空構造型材同士を接合できる。このためプロープ型の摩擦攪拌回転ツールを用いる場合のように、回転ツールを押し付ける力に抗するための架台など支持部材を必要としないので、このような支持部材の準備や取り外しという操作が不要となり、製造方法が簡単になる。
【００２０】
また、一の板の先端同士の間を摩擦攪拌接合用回転ツールの移動空間とできるため、他の板同士を接合するに際して、他の板の外側から摩擦攪拌接合用回転ツールを用いる必要がなく、一の板の側からの作業ですむ。一の板同士は平板からなる継手板を介して接続するが、一の板と継手板との接合も一の板の側から作業でき、どちらの板の接合作業も一の板側からの作業となり、製造方法及びそれに必要な設備が簡単になる。
【００２１】
請求項６に記載の発明は、２つの板同士を摩擦接合して構造物を製造する構造物製造方法において、一方の板と他方の板との少なくとも一方に接着剤を塗布する工程と、次に、前記一方の板と前記他方の板とを接着剤を塗った箇所で接触させて配置する工程と、次に、前記一方の板と前記他方の板とを摩擦接合を行うことにより前記板同士を接合させる工程とからなることを特徴としている。
【００２２】
この構成により、板と板とを接着剤で固定することにより、簡単にしっかりと仮止めができる。特に、接合する板同士に構造的な仮止め構造が設けられていない場合に有効である。
【００２３】
請求項７に記載の発明は、請求項５に記載の構造物製造方法において、前記継手板と前記一の板とを摩擦攪拌により接合する前に、前記継手板と前記一の板との少なくともいずれか一方に接着剤を塗布する工程を含むことを特徴としている。
【００２４】
この構成により、一の板と継手板とを接着剤で固定することにより、簡単にしっかりと仮止めできる。特に、接合する板同士に構造的な仮止め構造が設けられていない場合や設けられていても、中空構造型材が垂直に配置されていて構造的な仮止め構造の効果が期待できない場合に有効である。
【００２５】
【発明の実施の形態】
本発明の一実施形態について、図面を参照して説明する。
〈ボビン型摩擦攪拌回転ツール〉
摩擦接合をするため手段である摩擦攪拌接合回転ツールとして、ボビン型の摩擦攪拌接合回転ツール（以下単に「ボビンツール」と記す）３０を使用する。なお、以下において、特に断りがない限り、上とか下の語は絶対的な上下を規定する意図ではなく、相対的な関係を示しているにすぎず、配置によっては左右にも成り得るものである。
【００２６】
ボビンツール３０そのものは、公知の技術である。図２に示すようにボビンツール３０はピン３０ａ（請求項の「回転軸」に相当）をはさんで、略円柱状の上ショルダ３０ｂと略円柱状の下ショルダ３０ｃがある。ピン３０は円柱状であり、上ショルダ３０ａの下面（請求項の「対向する回転面」の一に相当）とこれに対抗する下ショルダ３０ｃの上面（請求項の「対向する回転面」の他の一に相当）の中心に接続固定されている。
【００２７】
上ショルダ３０ｂから連続する上方に広がり方向の円錐台形状の部分３０ｄがあり、この部分からさらに連続する上方にそれらよりも径の大きい略円柱状の部分３０ｅがある。この略円柱状の部分３０ｅ、円錐台形状の部分３０ｄ、上ショルダ３０ｂ、ピン３０ａ、下ショルダ３０ｃは一体となってそれらのセンターを貫く軸を中心に回転するものであり、図示していない回転駆動装置の駆動が略円柱状の部分３０ｅ側に伝えられて、これらが一体に回転する。
【００２８】
摩擦攪拌による固相接合は、ワークＷより実質的に固い材質からなる回転ツールの先端をワークＷの接合部に挿入し、回転ツールを回転させながら移動することにより、回転ツールとワークＷの間に生じる摩擦熱による塑性流動によってワークＷを接合する。ボビンツール３０では、摩擦攪拌接合に必要な摩擦熱を発生させるため、上下ショルダ３０ｂ、３０ｃの間隔は接合するワークＷの厚さよりやや狭くなっている。
【００２９】
このため、上下ショルダ３０ｂ、３０ｃとワークＷの間に押し付け力が発生し、摩擦攪拌接合に必要な摩擦熱が発生する。ワークＷとなる部材は、例えばアルミニウム合金などの摩擦攪拌接合の可能な部材からなる。このワークＷは、後述する中空構造材を構成する板や継手板に相当するものである。
【００３０】
〈ボビン型摩擦攪拌回転ツールの利点〉
ボビンツール３０によれば、押し付け力は上下ショルダ３０ｂ、３０ｃとワークＷに同時に、反対向きに発生し、互いに打ち消しあうから、ワークＷに対して一方の側のみから押し付け力を作用させて摩擦攪拌を行うプローブ型の回転ツールのように、支持部材１３を設けて、押し付け力を支持しなくてもワークＷが曲がって変形することはない。
【００３１】
また、摩擦攪拌接合の一般的な利点として、接合部分を溶融させることなく接合できるので加熱温度が低く、接合後のワークＷの変形がほとんどなく、接合部分は溶融されていないため、欠陥が少ない。
【００３２】
〈中空構造型材〉
図１の各図には、互いに接合される２つの中空構造型材４０が左右に並んで配置されている。中空構造型材４０である二面中空パネル４０ともいい、対向する２つの板４０ａ、４０ｂと両板４０ａ、４０ｂを接続支持する複数のリブ板４０ｃからなるハニカム構造である。複数のリブ板４０ｃはトラス状に配置され、複数のリブ板４０ｃの前記板４０ａ、４０ｂに対する傾斜方向は交互に反転している。この構造型材４０はアルミニウム合金などの摩擦攪拌接合可能な部材からなり、一般的には、押出しにて成形される。
【００３３】
図１（ａ）に示すように、接合する中空構造型材４０の下側の面板４０ｂを長くしておく。更に、中空構造型材４０の上側（作業する方から見て近い側）の面板４０ａは下面板４０ａよりも短い位置で切断し、または、中空構造型材４０の成形時に短い形状として押出し成形し、他方の中空構造型材４０の上面板４０ａとの間に間隔を設ける。即ち、対向する２つの板４０ａ、４０ｂは最も端のリブ板４０ｃとの接続部分よりも先端が延出しかつ前記対向する２つの板のうち一の板４０ａは他の板４０ｂよりも先端が短くなっている。
【００３４】
更に、上面板４０ａと下面板４０ｂとを結合するリブ板４０ｃと上面板４０ａと下面板４０ｂの端部は所定の長さ（Ｌ１、Ｌ２、Ｍ１、Ｍ２）だけ突出し、上面板同士４０ａの間隔（Ｎ１、Ｎ２）は所定の長さだけ確保するように形成されている。
【００３５】
即ち、接合する中空構造型材４０のうち少なくとも一方の、一の板である上面板４０ａと他の板である下面板４０ｂとの先端の短さ（Ｎ１、Ｎ２）は摩擦攪拌接続用回転ツールの半径よりも大きく。両方の短さ（Ｎ１、Ｎ２）を合計して摩擦攪拌接続用回転ツール３０の直径よりも大きくしている。好ましくは、接合する中空構造型材４０の両方とも、同程度の短さ（Ｎ１、Ｎ２）とするのが良い。これにより、中空構造型材４０同士を接続して構造物を製造するときに、上面板４０ａと摩擦攪拌接続用回転ツール３０の両側に同程度の間隔をとることができ、摩擦攪拌接続用回転ツール３０の位置決めや操作がし易くなるからである。
【００３６】
対向する２つの板である上面板４０ａと下面板４０ｂ、それぞれにおいて、最も端のリブ板４０ｃとの接続部分よりも延出する部分の長さ（Ｌ１、Ｌ２、Ｍ１、Ｍ２）がボビンツール３０の上下ショルダ３０ｂ、３０ｃの回転面の半径よりも長くしてある。これにより、中空構造型材４０同士を接続して構造物を製造するときに、支障なくボビンツール３０を用いることができる。
【００３７】
〈構造体の製造方法〉
このボビンツール３０により、中空構造型材４０である二面中空パネル（別名、ダブルスキンパネル）同士、あるいは中空構造型材４０とその補助材や補強材等を、突合せにて接合し、車体などの構造物を製造する方法を、図１に基いて、以下に説明する。なお、図１では、図の見易さを考慮して、中空構造型材４０が水平に配置されているが、垂直に支持して配置した場合も同様であり、車体などの構造物の製造には、垂直に配置されている場合に、特に、本発明の効果が大きい。
【００３８】
最初に中空構造型材４０同士が連続するように並べて配置するに際して、一の板である上面板４０ａの先端同士は間隔を空けて、他の板である下面板４０ｂの先端同士は付き合わせて配置する。
【００３９】
次に、この下面板４０ｂ同士をボビンツール３０により接合する。即ち、ボビンツール３０を用いて、上下シャフト３０ｂ、３０ｃの回転面により下面板４０ｂを挟んで下面板４０ｂ同士を摩擦攪拌により接合させながら、ボビンツール３０を上面板４０ａの先端同士の間隔（Ｎ１、Ｎ２）からなる空間を移動させて、接合を完了する。
【００４０】
次に、図１（ｂ）に示すように、一の板４０ａ同士の間に継手板４１を配置する。即ち、上面板４０ａの先端と継手板４１の端とが付き合わさるように、上面板４０ａ同士の間に継手板４１がはまるように配置する。この場合、図３や図４に関連して後述する手段を用いることにより、継手板４１を一の板４０ａに対して固定し易くできる。
【００４１】
また、後に詳述するように、一の板４０ａ同士の間に前記継手板４１を配置する前に、予め、少なくともいずれか一方の板に接着剤を塗布しておくことにより、一の板４０ａ同士の間に前記継手板４１をしっかりと仮止めすることができて、中空構造型材４０を垂直に配置して接合するような場合であっても、継手板４１をしっかりと仮止めできる。
【００４２】
次に、図１（ｂ）に示すように、ボビンツール３０を用いて前記継手板４１と前記一の板４０ａとを摩擦攪拌により接合する。即ち、上下シャフト３０ｂ、３０ｃの回転面により上面板４０ａの一端と継手板４１の一端を挟んで上面板４０ａと継手板４１とを摩擦攪拌により接合させながら、ボビンツール３０を上面板４０ａの外側から移動操作させて、接合を完了する。
【００４３】
次に、図１（ｃ）に示すように、図１（ｂ）に関して説明したのと同様に、継手板４１の他端ともう一方の上面板４０ａをボビンツール３０で接合する。
こうすることにより、支持部材を設けることなく、片側から中空構造型材４０の上下面板４０ａ、４０ｂをそれぞれ接合することができる。
【００４４】
このように、上下２枚の面板４０ａ、４０ｂを有する中空構造型材４０を、片側から、しかも、摩擦攪拌回転ツールの押し付け力に抗するための強固な支持部材等の特別の補助装置を用いること無く、接合することができる。
【００４５】
〈継手板の位置決め固定〉
図３に示すように、上面板４０ａの側面と継手板４２の側面に段を付けて嵌め合わせできるようにすることが好ましい。即ち、上面板４０ａは外表面側にへこんだ段状に先端側面が形成され、継手板４２は上面板４０ａの先端側面と合わさる段状に端部が形成されている。この場合、上面板４０ａの先端側面の段状形状が外表面に向かってへこんでいるため、継手板４２を上面板４０ａの外側からはめやすく、上面板４０ａと継手板４２との段状同士により簡単に位置決め固定できる。
【００４６】
図３に示すように、上面板４０ａと継手板４２との両方に段状を形成することが固定の安定性からは好ましいが、上面板４０ａと継手板４１、４２の一方のみに段状を形成しても、固定できる。図４に示すように、継手板４１の端部を段状に形成せず、上面板４０ａだけに段状を形成してもよい。また、図５のように、継手板４２の端部を内表面となる側にへこんだ段状に形成してもよい。
【００４７】
図６に示すように、上面板４０ａの側面と継手板４３の側面に傾斜を設けて嵌め合わせできるようにすることが好ましい。特に、上面板４０ａの傾斜は外側に向かって開く方向、即ち、一の板４０ａは先端側面が一の板４０ａの内表面から外表面に向かって開いた傾斜面になっていることが好ましい。これにより、継手板４２を上面板４０に対し位置決め固定し易いのみならず、継手板４３を一の板４０ａの外側から嵌めやすく、かつ、継手板４３と一の板４０ａとの接合部分が傾斜面同士であるため隙間ができ難いので、摩擦攪拌接合した際の欠陥を生じ難い。
【００４８】
〈接着剤の使用〉
図５の接合のように、中空構造型材５０が垂直に配置されているところでの接合においては、上述のような図３〜図６に示したような継手板４１の位置決め固定手段が設けられていても、自重での位置決めが不安定となる。このような場合や中空構造材が水平に配置された場合であっても継手板４１の端部等に位置決め固定手段が施されていない場合には、１の板４０ａ同士の間に、継手板４１を配置する前に、一の板４０ａの端部と継手板４１の端部との少なくとも一方に接着剤等を塗布して継手板４１板を一の板４０ａに仮付けしておくのが望ましい。
【００４９】
これにより、継手板４１板を一の板４０ａに簡単にしっかりと仮止めできる。なお、接着剤による仮止めによれば、摩擦接合で恒久的な固定ができた後に、仮止めのための部材や装置を除くなどの後処理作業の必要もないため、構造物製造方法が簡単になる。接着剤としては、シアノアクリルレート系、低温硬化エポキシ系、２液高性能エポキシ系やアクリル系等の接着剤の内で、摩擦攪拌接続により部材などが温度上昇するが、この温度上昇に起因するガス発生、例えば燃焼ガスの少ない接着剤を用いるのが好ましい。ガス発生が多い場合、作業空間の換気作業や換気設備の負担が多くなるからである。
【００５０】
〈接合の強度を上げる凸部〉
図７に示す中空構造型材４４のごとく、下面板４４ｂの接合箇所に接合相手の下面板４０ｂと重ね合わせとなる凸部４４ｃを設けることにより、接合の強度を上げることも可能である。なお、このように接合の強度を上げるための凸部４４ｃは接合箇所だけに設ければよく、接合箇所から離れたところの板厚までも厚くする必要はない。
【００５１】
図４、図５に示すように、上面板と継手板の接合箇所においても、いずれか一方の板に他方の板と重ね合わせとなる凸部を設けることは、下面板４０ｂ、４４ｂの場合と同様に、接合箇所の強度を上げることができる。この場合も、接合箇所のみに凸部があればよく、接合箇所と関係しないところの板厚までも厚くする必要はない。
【００５２】
〈鉄道車両の車体〉
本発明は、広く適応できるものであるが、好適な例として、鉄道車両の車体への適応について説明する。図８は鉄道車両の車体全体の概略断面構成を示し、符号Ｋの矢印の先にある箇所が中空構造型材５０、５１同士の接合箇所となる。図１では、中空構造型材を水平にした状態が示されているが、車体などに適応する場合には、垂直にした状態に配置される。
【００５３】
即ち、中空構造型材５０、５１同士の接合については図１に関する説明と基本的には同じであり、図８のＫの矢印の先の円印の箇所に適応した場合、図１の各図を右に９０度回転させた状態の配置となる。
【００５４】
図８に示すように、中空構造型財５０、５１を突合せて、立体的に配置し支持する。ボビンツール３０を車体の外側から挿入して、先ず、屋根構体１を構成する中空構造型材５０の車体内側の板（図１の左側の他の板４０ｂに相当）と側構体２を構成する中空構造型材５１の車体内側の板（図１の右側の他の板４０ｂに相当）とを接合する。図８に示す側構体２の断面の白抜きの部分は、窓が設置されることを想定しているが、中空構造型材５１がそのまま連続している場合もある。
【００５５】
次に、屋根構体１を構成する中空構造型材５０の外面板（図１の左側の一の板４０ａに相当）と側構体２を構成する中空構造型材５１の外面板（図１の右側の一の板４０ａに相当）との間に継手板（図１の継手板４１に相当）はめる。
【００５６】
次に、ボビンツール３０を用いて、継手板と屋根構体１を構成する中空構造型材５０の外面板（図１の左側一の板４０ａに相当）とを接合する。次に、継手板と側構体２を構成する中空構造型材５１の外面板（図１の右側の一の板４０ａに相当）とを接合する。
【００５７】
この場合、ボビンツール３０を中空構造型材５０、５１に車体の外側からのみ挿入でき、車体の内部にボビンツール３０を移動させる機器を設ける必要がなく、また、ボビンツール３０のある反対側、即ち、車両の内部に摩擦攪拌接合回転ツールの押し付け力に抗する支持部材を設ける必要がないことが、製造設備を簡単にし、製造作業も簡易としている。
【００５８】
また、従来のＭＩＧ溶接や埋れアーク溶接による場合と比較して、摩擦攪拌接合の採用により、接合部を溶融させることなく接合できるので加熱温度が低く、接合後の変形が少なく、且つ、歪や欠陥が少ないと言う利点を享受できる。従って、装置点数の大幅な削減、及び、製造作業工数の大幅な節減ができるとともに作業性の向上、及び、品質の向上が図れる。
【００５９】
さらに、上述したように、継手板４１を接着剤で仮付けすることにより、構造の簡素化、作業性の向上が図れる。また、上述したように、継手板４２、４３の端部に設けた段や斜面により位置決めが容易となり、作業性の向上が図れる。
【００６０】
以上、説明は図８に示すような、垂直に配置された構体同士の組立時の接合について述べたが、中空構造型材同士を略水平な状態に於いて接合し、構体を製作する場合にあっても、前述のように片側から、しかも、支持部材等の特別の補助装置を用いること無く、接合することができるので、中空構造型材の支持装置は自重を支える程度の簡易なもので良く、また、片面を接合した後で反対面を接合するために反転する必要が無い。
【００６１】
このことから、略水平な状態に配置した中空構造型材同士の接合の場合にあっても装置の簡素化、作業性の向上が図れる。部品点数及び組立工数を節減できるとともに作業性の向上と相俟って制作期間の短縮化が図れ、生産性の向上と大幅なコストダウンにより、堅牢で軽量な車両を安価に提供することができる。
【００６２】
なお、本発明は、車両の構体の製造に適したものとして説明をしているが、航空機、及び、船舶等の構体を形成する中空材を突合せて摩擦攪拌接合する場合にあっても適用できる。
【００６３】
【発明の効果】
以上説明した本発明においては以下の効果を奏する。
請求項１記載の発明によれば、中空構造型材同士を接合して構造物を製造するときに、中空構造型材が一の板も他の板もリブ板との接続部分よりも延出している部分を有する構成であるため、その部分をボビン型摩擦攪拌接合用回転ツールの回転面間で挟むことができ、ボビン型摩擦攪拌接合用回転ツールを用いて中空構造型材同士を接合できる。このためプロープ型の摩擦攪拌回転ツールを用いる場合のように、回転ツールを押し付ける力に抗するための支持部材を必要としない。
【００６４】
また、一の板の先端同士の間を摩擦攪拌接合用回転ツールの移動空間とすることができるため、他の板同士を接合するに際して、他の板の外側から摩擦攪拌接合用回転ツールを用いる必要がなく、中空構造型材を反転させることなく、一の板の側からの作業ですむ。一の板同士は平板からなる継手板を介して接続するが、一の板と継手板との接合も一の板の側から作業でき、どちらの板の接合作業も一の板側からの作業となり、作業及びそれに必要な設備が簡単になる。
【００６５】
請求項２記載の発明によれば、中空構造型材同士を接合するときに、継手板を一の板同士の間にはめて、継手板を介して一の板同士を接続するが、継手板を一の板の表側からはめて、継手板を一の板に対して位置決め固定できるので、操作が簡単である
【００６６】
請求項３記載の発明によれば、中空構造型材同士を接合するときに、継手板を一の板同士の間にはめて、継手板を介して一の板同士を接続するが、一の板の先端側面の段状形状が外表面側でへこんでいるため、又は、継手板の端部が内表面となる側でへこんであるため、継手板を一の板の外側からはめやすく、一の板と継手板との段状同士により簡単に位置決め固定できる。一の板と継手板の両方に段状を形成すると固定したときにより安定性がある。
【００６７】
請求項４記載の発明によれば、中空構造型材同士を接合するときに、一の板の先端側面の傾斜面に合わさる傾斜面を側面にもつ継手板を介して一の板同士を接続するが、一の板の先端側面は一の板の内表面から外表面に向かって開いた傾斜となっているため、継手板を一の板の外側からはめやすく、簡単に位置決め固定でき、かつ、継手板材と一の板との接合部分が傾斜面同士であるため、隙間ができ難いので、摩擦攪拌接合したときに欠陥が生じ難い。
【００６８】
請求項５記載の発明によれば、中空構造型材同士を接合して構造物を製造するときに、中空構造型材が一の板も他の板もリブ板との接続部分よりも延出している部分を有する構成であるため、その部分をボビン型摩擦攪拌接合用回転ツールの回転面間で挟むところにでき、ボビン型摩擦攪拌接合用回転ツールを用いて中空構造型材同士を接合できる。このためプロープ型の摩擦攪拌回転ツールを用いる場合のように、回転ツールを押し付ける力に抗するための架台などの冶具を必要としないので、冶具の準備や取り外しという操作が不要となり、製造方法が簡単になる。
【００６９】
また、一の板の先端同士の間を摩擦攪拌接合用回転ツールの移動空間とできるため、他の板同士を接合するに際して、他の板の外側から摩擦攪拌接合用回転ツールを用いる必要がなく、一の板の側からの作業ですむ。一の板同士は平板からなる継手板を介して接続するが、一の板と継手板との接合も一の板の側から作業でき、どちらの板の接合作業も一の板側からの作業となり、製造方法及びそれに必要な設備が簡単になる。
【００７０】
請求項６記載の発明によれば、板と板とを接着剤で固定することにより、簡単にしっかりと仮止めができる。特に、接合する板同士に構造的な仮止め構造が設けられていない場合に有効である。
【００７１】
請求項７記載の発明によれば、一の板と継手板とを簡単にしっかりと仮止めできる。特に、接合する板同士に構造的な仮止め構造が設けられていない場合や設けられていても、中空構造型材が垂直に配置されていて構造的な仮止め構造の効果が期待できない場合に有効である。
【図面の簡単な説明】
【図１】本発明の一実施形態に係る構造物製造方法及び中空構造型材を示す断面図
【図２】本発明の一実施形態に係るボビンツールでの接合を示す断面図
【図３】本発明の一実施形態に係る板同士の位置決め固定のための形状を示す断面図
【図４】本発明の別の実施形態に係る板同士の位置決め固定のための形状を示す断面図
【図５】本発明の別の実施形態に係る板同士の位置決め固定のための形状を示す断面図
【図６】本発明の別の実施形態に係る板同士の位置決め固定のための形状を示す断面図
【図７】本発明の別の実施形態に係る他の板同士の接合を示す断面図
【図８】本発明の一実施形態に係る車両の車体の製造途中の概略断面図
【図９】従来の構造物製造方法及び中空構造型材を示す断面図
【符号の説明】
１…屋根構体
２…側構体
３…床構体
１１…プローブ型回転ツール
１２…形状保持材
１３…支持部材
２０…中空パネル
２０ａ…上面板
２０ｂ…垂直リブ
２０ｃ…下面板
２１…継手板
３０…ボビンツール
３０ａ…ピン
３０ｂ…上ショルダ
３０ｃ…下ショルダ
４０…中空構造型材
４０ａ…上面板
４０ｂ…下面板
４０ｃ…リブ
４１…継手板
４２…継手板（段付き）
４３…継手板（傾斜付き）
４４…中空材
４４ｂ…下面板
４４ｃ…凸部
５０…中空構造型材
５１…中空構造型材
Ｋ…接合部
Ｗ…ワーク
Ｌ１、Ｌ２…リブ板からの一の板（上面板）の突出し量
Ｍ１、Ｍ２…リブ板からの他の板（下面板）の突出し量
Ｎ１、Ｎ２…一の板（上面板）と他の板（下面板）との先端の短さ[0001]
TECHNICAL FIELD OF THE INVENTION
Using a rotary tool for friction stir welding, a technology for manufacturing a structure by joining hollow structural members having a honeycomb structure made of a plate that can be joined by friction stir, particularly using a bobbin type friction stir welding rotary tool The present invention relates to a hollow structural member suitable for joining and a method for manufacturing a structure using the hollow structural member.
[0002]
[Prior art]
Conventionally, as a railway vehicle structure, a left and right side structure, a floor structure, a roof structure, and the like of a vehicle use a long hollow structural member extending in a longitudinal direction, and the hollow structural member is joined only in the longitudinal direction. There are known structures that constitute the side structure, floor structure, roof structure, and the like (for example, see Patent Document 1).
[0003]
Regarding such joining of hollow structural members, as shown in FIG. 9, the hollow panel 20, which is a hollow structural member, has a shape in which a lower surface plate 20c extends from a vertical rib 20b. The lower plate 20c is first joined to the lower plate 20c and joined, and then a joint plate 21 is fitted to the upper part of the protruding lower plate 20c, and both ends of the joint plate 21 are joined to the upper plate 20a. It is known that the upper and lower plates of the hollow panel 20 can be joined from only one side by doing so.
[0004]
However, since the friction stir welding rotary tool 11 employs a probe type that performs friction stir welding by pressing a rotating surface from only one side against a plate to be joined, a frame (bed) or the like for supporting a force pressing against the face plate is used. A support member 13 is required (for example, see Patent Document 2).
[0005]
[Patent Document 1]
JP-A-2-246683 (page 2, FIG. 1)
[Patent Document 2]
JP-A-11-314181 (paragraph 0027, FIG. 9)
[0006]
[Problems to be solved by the invention]
By the way, according to such a conventional technique, when a structure such as a vehicle is manufactured by friction stir welding using a hollow structural member, a support member such as a gantry is required. When the hollow structural members are arranged and joined in a horizontal state, a support member such as a pedestal is required, but the structure of the pedestal or the like and the installation of the hollow structural members on the pedestal or the like are also easy.
[0007]
However, when assembling the roof structure, side structure, and floor structure as subunits to complete the car body, in the final process, since each structure is arranged three-dimensionally, there are places to join in a vertical state, There is also a need to install a support member for supporting the surface inside the vehicle body, and setting such a support member at each joint is a cumbersome operation and requires excessive facilities.
[0008]
The present invention has been made in view of the above circumstances, and in order to solve this problem, the friction stir welding tool can be moved only from one side of the hollow structural members to join the hollow structural members, and Hollow structural member suitable for joining using a bobbin-type friction stir welding rotary tool that performs friction stir welding by sandwiching a plate to be joined between two opposing rotating surfaces so that members need not be provided, and It is an object of the present invention to provide a method for manufacturing a structure using the method.
[0009]
[Means for Solving the Problems]
The present invention employs the following means in order to solve the above problems.
The invention according to claim 1 is a hollow structural member composed of two opposing plates and a plurality of rib plates for connecting and supporting the two plates, wherein the two opposing plates are connected to the endmost rib plate. The tip is extended more than one, and one of the two opposing plates has a tip shorter than the other plate.
[0010]
With this configuration, when manufacturing a structure by joining hollow structural members together, the hollow structural member has a portion in which one plate and the other plate extend beyond the connection portion with the rib plate. Therefore, the portion can be sandwiched between the rotating surfaces of the bobbin-type friction stir welding rotary tool, and the hollow structural members can be joined together using the bobbin-type friction stir welding rotary tool. Therefore, unlike the case of using a probe-type friction stir rotation tool, there is no need for a support member for resisting the force pressing the rotation tool.
[0011]
In addition, since the space between the tips of one plate can be used as the moving space of the rotary tool for friction stir welding, when joining the other plates, the rotary tool for friction stir welding is used from outside the other plate. There is no need to work from the side of one plate, without having to flip the hollow structural profile. The one plate is connected via a flat joint plate, but the joining of the one plate and the joint plate can also be performed from the one plate side, and the joining work of both plates is from the one plate side This simplifies the work and the equipment required for it.
[0012]
According to a second aspect of the present invention, in the hollow structural member according to the first aspect, a joint plate can be connected to a distal end of the one plate, and the joint plate is fitted from an outer surface side of the one plate. It is characterized in that a joint shape for positioning and fixing is formed.
[0013]
With this configuration, when joining the hollow structural members, the joint plates are fitted between the one plates and the one plates are connected via the joint plates, but the joint plates are connected to the outer surface of the one plate. The operation is simple because the joint plate can be positioned and fixed to one plate by being fitted from the side.
[0014]
According to a third aspect of the present invention, in the hollow structural member according to the first aspect, the joint shape is formed such that a tip side surface of the one plate is stepped toward an outer surface. I have.
[0015]
With this configuration, when joining the hollow structural members, the joint plates are fitted between the one plates, and the one plates are connected via the joint plates. Since the shape is recessed on the outer surface side, the joint plate can be easily fitted from the outside of one plate, and can be easily positioned and fixed. Further, for example, when the joint plate is formed in a stepped shape, the joint plate is more stable than when it is fixed.
[0016]
According to a fourth aspect of the present invention, in the hollow structural member according to the first aspect, as the joint shape, an inclined surface in which a tip side surface of the one plate opens from an inner surface to an outer surface of the one plate. It is characterized by being formed in.
[0017]
With this configuration, when joining hollow structural members, when connecting one plate via a joint plate having an inclined surface on a side surface that matches the inclined surface on the distal side surface of one plate, the distal side surface of the one plate Is inclined from the inner surface to the outer surface of the one plate, so that the joint plate can be easily fitted from the outside of the one plate, can be easily positioned and fixed, and the joint plate and the one plate Since the joining portions are inclined surfaces, it is difficult to form a gap, so that defects are less likely to occur when friction stir welding is performed.
[0018]
The invention according to claim 5 is a structure manufacturing method for manufacturing a structure by frictionally bonding hollow structural members composed of two opposing plates and a plurality of rib plates that connect and support the two plates, The two opposing plates have a tip extending beyond the connection portion with the respective end rib plates, and one of the two opposing plates is the hollow structural member having a tip shorter than the other plate. A bobbin-type friction stir welding rotary tool having a rotating surface facing the rotating surface and a rotating shaft connecting the rotating surface at a tip is moved in a space formed by an interval between the tips of one plate to friction the other plates. It is characterized by comprising a step of joining by stirring and a step of joining the joint plate and the one plate by friction stirring using the rotary tool for bobbin-type friction stir welding.
[0019]
According to this configuration, when a structure is manufactured by joining the hollow structural members together, the hollow structural member has a portion in which one plate and the other plate extend beyond the connection portion with the rib plate. Therefore, the portion can be sandwiched between the rotating surfaces of the bobbin-type friction stir welding rotary tool, and the hollow structural members can be joined to each other using the bobbin-type friction stir welding rotary tool. Therefore, unlike the case of using a probe-type friction stir rotation tool, there is no need for a support member such as a gantry for resisting the pressing force of the rotation tool, so that the operation of preparing and removing such a support member is not required. And the manufacturing method is simplified.
[0020]
In addition, since the space between the ends of one plate can be used as a moving space for the friction stir welding rotary tool, it is not necessary to use the friction stir welding rotary tool from the outside of the other plate when joining the other plates. You only have to work from the side of one board. The one plate is connected via a flat joint plate, but the joining of the one plate and the joint plate can also be performed from the one plate side, and the joining work of both plates is from the one plate side This simplifies the manufacturing method and the necessary equipment.
[0021]
The invention according to claim 6 is a structure manufacturing method for manufacturing a structure by frictionally joining two plates to each other, wherein an adhesive is applied to at least one of one plate and the other plate; A step of arranging the one plate and the other plate in contact with each other at a place where the adhesive is applied, and then performing the friction bonding between the one plate and the other plate to form the plate. And joining them together.
[0022]
With this configuration, by temporarily fixing the plates with an adhesive, temporary fixing can be easily and firmly performed. In particular, it is effective when a structural temporary fixing structure is not provided between the plates to be joined.
[0023]
According to a seventh aspect of the present invention, in the structure manufacturing method according to the fifth aspect, before joining the joint plate and the one plate by friction stirring, at least the joint plate and the one plate are joined together. The method is characterized by including a step of applying an adhesive to one of them.
[0024]
With this configuration, the one plate and the joint plate can be easily and firmly temporarily fixed by fixing the joint plate with the adhesive. Especially effective when the structural temporary fixing structure is not provided between the plates to be joined or even when it is provided, the hollow structural members are arranged vertically and the effect of the structural temporary fixing structure cannot be expected. It is.
[0025]
BEST MODE FOR CARRYING OUT THE INVENTION
An embodiment of the present invention will be described with reference to the drawings.
<Bobbin type friction stir rotation tool>
A bobbin-type friction stir welding rotary tool (hereinafter simply referred to as "bobbin tool") 30 is used as a friction stir welding rotary tool as a means for performing friction welding. In the following, unless stated otherwise, the terms above and below are not intended to define absolute upper and lower directions, but merely indicate a relative relationship, and may be left or right depending on the arrangement. is there.
[0026]
The bobbin tool 30 itself is a known technique. As shown in FIG. 2, the bobbin tool 30 has a substantially cylindrical upper shoulder 30b and a substantially cylindrical lower shoulder 30c sandwiching a pin 30a (corresponding to a "rotating shaft" in the claims). The pin 30 has a columnar shape, and includes a lower surface of the upper shoulder 30a (corresponding to one of the "opposing rotating surfaces") and an upper surface of the lower shoulder 30c opposed thereto (the "opposing rotating surface"). (Corresponding to one).
[0027]
There is a truncated conical portion 30d extending in the upward direction continuing from the upper shoulder 30b, and a substantially columnar portion 30e having a larger diameter than these is further continuing upward from this portion. The substantially cylindrical portion 30e, the truncated conical portion 30d, the upper shoulder 30b, the pin 30a, and the lower shoulder 30c are integrally rotated about an axis passing through the center thereof, and are not shown. The driving of the driving device is transmitted to the substantially cylindrical portion 30e side, and these rotate integrally.
[0028]
Solid-state welding by friction stirring is performed by inserting the tip of a rotating tool made of a material substantially harder than the work W into the joint of the work W and moving the rotating tool while rotating the rotating tool to thereby rotate the rotating tool and the work W. Work W is joined by plastic flow caused by frictional heat generated in the work. In the bobbin tool 30, the interval between the upper and lower shoulders 30b and 30c is slightly smaller than the thickness of the workpiece W to be joined in order to generate frictional heat required for friction stir welding.
[0029]
For this reason, a pressing force is generated between the upper and lower shoulders 30b and 30c and the work W, and frictional heat required for friction stir welding is generated. The member to be the work W is a member capable of friction stir welding such as an aluminum alloy. The work W corresponds to a plate or a joint plate constituting a hollow structural member described later.
[0030]
<Advantages of bobbin type friction stir rotation tool>
According to the bobbin tool 30, the pressing force is simultaneously generated in the upper and lower shoulders 30b and 30c and the work W in the opposite directions, and cancels each other. Therefore, the pressing force is applied to the work W from only one side to friction stir. The work W is not bent and deformed even if the support member 13 is provided and the pressing force is not supported as in a probe-type rotary tool for performing the above.
[0031]
Further, as a general advantage of the friction stir welding, since the joining can be performed without melting the joining portion, the heating temperature is low, the work W after the joining hardly deforms, and the joining portion is not melted, so that there are few defects. .
[0032]
<Hollow structural material>
In each figure of FIG. 1, two hollow structural members 40 joined to each other are arranged side by side. It is also called a two-sided hollow panel 40 which is a hollow structural member 40, and has a honeycomb structure including two opposing plates 40a, 40b and a plurality of rib plates 40c for connecting and supporting the two plates 40a, 40b. The plurality of rib plates 40c are arranged in a truss shape, and the inclination directions of the plurality of rib plates 40c with respect to the plates 40a and 40b are alternately reversed. The structural member 40 is made of a member capable of friction stir welding such as an aluminum alloy, and is generally formed by extrusion.
[0033]
As shown in FIG. 1A, the lower face plate 40b of the hollow structural member 40 to be joined is made longer. Further, the face plate 40a on the upper side (closer side as viewed from the working side) of the hollow structural member 40 is cut at a position shorter than the lower surface plate 40a, or is extruded as a short shape when the hollow structural member 40 is formed. Is provided between the hollow structural member 40 and the upper surface plate 40a. That is, the leading ends of the two opposing plates 40a and 40b extend beyond the connection with the endmost rib plate 40c, and the leading end of one of the two opposing plates 40a is shorter than the other plate 40b. Has become.
[0034]
Further, the ends of the rib plate 40c, the upper plate 40a, and the lower plate 40b that connect the upper plate 40a and the lower plate 40b project by a predetermined length (L1, L2, M1, M2), and the distance between the upper plates 40a. (N1, N2) is formed so as to secure a predetermined length.
[0035]
That is, at least one of the hollow structural members 40 to be joined, the length (N1, N2) of the tip of the upper plate 40a, which is one plate, and the lower plate 40b, which is the other plate, is smaller than that of the rotary tool for friction stir connection. Larger than radius. The sum of both shortnesses (N1, N2) is larger than the diameter of the rotary tool 30 for friction stir connection. Preferably, both of the hollow structural members 40 to be joined have the same length (N1, N2). Thereby, when manufacturing the structure by connecting the hollow structural members 40 to each other, the upper plate 40a and both sides of the rotary tool 30 for friction stir connection can be equally spaced, and the rotary tool for friction stir connection can be obtained. This is because the positioning and operation of the 30 become easier.
[0036]
The length (L1, L2, M1, M2) of each of the two opposing plates, the upper plate 40a and the lower plate 40b, extending beyond the connection with the endmost rib plate 40c is the bobbin tool 30. Of the upper and lower shoulders 30b, 30c. This allows the bobbin tool 30 to be used without any trouble when connecting the hollow structural members 40 to manufacture a structure.
[0037]
<Structure manufacturing method>
The bobbin tool 30 joins the two-sided hollow panels (also called double-skin panels), which are the hollow structural members 40, or the hollow structural members 40 and their auxiliary members and reinforcing members by butt-joining to form a structure such as a vehicle body. The method for manufacturing the product will be described below with reference to FIG. In FIG. 1, the hollow structural members 40 are arranged horizontally in consideration of the legibility of the figure, but the same applies to the case where the hollow structural members 40 are vertically supported and arranged. The effect of the present invention is particularly great when they are arranged vertically.
[0038]
First, when the hollow structural members 40 are arranged side by side so as to be continuous with each other, the tips of the upper plate 40a, which is one plate, are spaced apart, and the tips of the lower plate 40b, which is the other plate, are arranged side by side. I do.
[0039]
Next, the lower plates 40b are joined together by the bobbin tool 30. That is, using the bobbin tool 30, the lower plate 40b is joined to each other by friction stirring while sandwiching the lower plate 40b by the rotating surfaces of the upper and lower shafts 30b, 30c, and the bobbin tool 30 is spaced from the tip of the upper plate 40a (N1). , N2) is moved to complete the joining.
[0040]
Next, as shown in FIG. 1B, a joint plate 41 is arranged between the plates 40a. That is, the joint plates 41 are arranged so as to fit between the upper plates 40a such that the ends of the upper plates 40a and the ends of the joint plates 41 abut each other. In this case, the joint plate 41 can be easily fixed to one plate 40a by using a unit described later with reference to FIGS.
[0041]
Further, as described later in detail, before disposing the joint plate 41 between the one plate 40a, an adhesive is applied to at least one of the plates in advance, so that the one plate 40a The joint plate 41 can be temporarily fixed firmly between them, and even when the hollow structural members 40 are vertically arranged and joined, the joint plate 41 can be temporarily fixed firmly.
[0042]
Next, as shown in FIG. 1B, the joint plate 41 and the one plate 40a are joined by friction stirring using a bobbin tool 30. That is, the bobbin tool 30 is moved to the outside of the upper surface plate 40a while frictionally stirring the upper surface plate 40a and the joint plate 41 so that one end of the upper surface plate 40a and one end of the joint plate 41 are sandwiched by the rotating surfaces of the upper and lower shafts 30b and 30c. To complete the joining.
[0043]
Next, as shown in FIG. 1C, the other end of the joint plate 41 and the other upper surface plate 40a are joined by the bobbin tool 30, as described with reference to FIG. 1B.
In this way, the upper and lower plates 40a and 40b of the hollow structural member 40 can be joined from one side without providing a support member.
[0044]
As described above, the hollow structural member 40 having the upper and lower two face plates 40a and 40b is provided with a special auxiliary device such as a strong supporting member for resisting the pressing force of the friction stir rotating tool from one side. And can be joined.
[0045]
<Fixing plate positioning and fixing>
As shown in FIG. 3, it is preferable that the side surface of the upper surface plate 40a and the side surface of the joint plate 42 be fitted with a step. That is, the top plate 40a is formed with a stepped end surface on the outer surface side, and the joint plate 42 is formed with a stepped end that matches the front end surface of the top plate 40a. In this case, since the stepped shape of the tip end side surface of the upper surface plate 40a is dented toward the outer surface, the joint plate 42 is easily fitted from the outside of the upper surface plate 40a, and the stepped shape of the upper surface plate 40a and the joint plate 42 Easy positioning and fixing.
[0046]
As shown in FIG. 3, it is preferable to form a step on both the upper plate 40 a and the joint plate 42 from the standpoint of fixing stability. However, a step is formed on only one of the upper plate 40 a and the joint plates 41 and 42. Even if it is formed, it can be fixed. As shown in FIG. 4, the end of the joint plate 41 may not be formed in a step shape, but may be formed in a step shape only on the upper surface plate 40a. Further, as shown in FIG. 5, the end of the joint plate 42 may be formed in a stepped shape dented on the side to be the inner surface.
[0047]
As shown in FIG. 6, it is preferable that the side surface of the upper surface plate 40a and the side surface of the joint plate 43 are provided with an inclination so that they can be fitted. In particular, it is preferable that the inclination of the upper surface plate 40a is a direction in which it opens outward, that is, the one plate 40a has an inclined surface whose front end surface is open from the inner surface to the outer surface of the one plate 40a. Thereby, not only is it easy to position and fix the joint plate 42 with respect to the upper surface plate 40, it is also easy to fit the joint plate 43 from outside the one plate 40a, and the joint between the joint plate 43 and the one plate 40a is inclined. Since there is no gap between the surfaces, it is difficult to form a defect when friction stir welding is performed.
[0048]
<Use of adhesive>
In the joining where the hollow structural members 50 are arranged vertically as in the joining of FIG. 5, the positioning and fixing means of the joint plate 41 as shown in FIGS. 3 to 6 as described above is provided. However, positioning with its own weight becomes unstable. In such a case, or even when the hollow structural members are arranged horizontally, if the positioning and fixing means is not applied to the end of the joint plate 41 or the like, the joint plate is placed between the one plate 40a. Before arranging the 41, an adhesive or the like is applied to at least one of the end of the one plate 40a and the end of the joint plate 41 to temporarily attach the joint plate 41 to the one plate 40a. desirable.
[0049]
As a result, the joint plate 41 can be temporarily and easily fixed to the one plate 40a. According to the temporary fixing by the adhesive, the structure manufacturing method is simple because there is no need for post-processing work such as removing the members and devices for the temporary fixing after the permanent fixing can be achieved by friction bonding. become. As the adhesive, among the adhesives of cyanoacrylate type, low-temperature curing epoxy type, two-pack high performance epoxy type, acrylic type, etc., the members and the like increase in temperature due to friction stir connection. It is preferable to use an adhesive that generates less gas, for example, less combustion gas. This is because when the amount of generated gas is large, the work of ventilating the work space and the load on the ventilation equipment increase.
[0050]
<Protrusions that increase bonding strength>
As in the case of the hollow structural member 44 shown in FIG. 7, by providing a convex portion 44c which is overlapped with the lower surface plate 40b of the mating partner at the position where the lower surface plate 44b is bonded, the bonding strength can be increased. In this case, the protrusion 44c for increasing the bonding strength may be provided only at the joint, and it is not necessary to increase the thickness of the sheet away from the joint.
[0051]
As shown in FIG. 4 and FIG. 5, even in the joint portion between the upper plate and the joint plate, providing a convex portion that is superimposed on one of the plates with the other plate is different from the case of the lower plates 40 b and 44 b. Similarly, the strength of the joint can be increased. Also in this case, it is sufficient that only the joint portion has the convex portion, and it is not necessary to increase the thickness of the portion not related to the joint portion.
[0052]
<Body of railway vehicle>
Although the present invention can be widely applied, as a preferred example, adaptation to a vehicle body of a railway vehicle will be described. FIG. 8 shows a schematic cross-sectional configuration of the entire vehicle body of the railway vehicle, and the portion at the tip of the arrow indicated by the symbol K is a joint portion between the hollow structural members 50 and 51. FIG. 1 shows a state in which the hollow structural member is horizontal, but when the hollow structural member is adapted to a vehicle body or the like, the hollow structural member is disposed in a vertical state.
[0053]
That is, the joining of the hollow structural members 50 and 51 is basically the same as that described with reference to FIG. 1. When the hollow structural members 50 and 51 are applied to the locations indicated by the circles in front of the arrow K in FIG. The arrangement is such that it is rotated 90 degrees to the right.
[0054]
As shown in FIG. 8, the hollow structural goods 50 and 51 are butted, arranged three-dimensionally, and supported. The bobbin tool 30 is inserted from the outside of the vehicle body, and first, a plate (corresponding to another plate 40b on the left side in FIG. 1) of the hollow structural member 50 forming the roof structure 1 and the hollow structure forming the side structure 2 are formed. A plate (corresponding to another plate 40b on the right side in FIG. 1) of the structural member 51 on the vehicle body side is joined. The white portion of the cross section of the side structure 2 shown in FIG. 8 is assumed to have a window, but the hollow structural member 51 may be continuous as it is.
[0055]
Next, an outer plate (corresponding to one plate 40a on the left side in FIG. 1) of the hollow structural member 50 constituting the roof structure 1 and an outer panel of a hollow structural member 51 constituting the side structure 2 (one right plate in FIG. 1). (Corresponding to the joint plate 41 of FIG. 1).
[0056]
Next, using the bobbin tool 30, the joint plate and the outer surface plate (corresponding to the plate 40a on the left side in FIG. 1) of the hollow structural member 50 constituting the roof structure 1 are joined. Next, the joint plate and the outer surface plate (corresponding to one plate 40a on the right side in FIG. 1) of the hollow structural member 51 constituting the side structure 2 are joined.
[0057]
In this case, the bobbin tool 30 can be inserted into the hollow structural members 50 and 51 only from outside the vehicle body, and there is no need to provide a device for moving the bobbin tool 30 inside the vehicle body. In addition, there is no need to provide a support member inside the vehicle against the pressing force of the friction stir welding rotary tool, which simplifies the manufacturing equipment and the manufacturing operation.
[0058]
In addition, compared to conventional MIG welding or buried arc welding, friction stir welding enables joining without melting the joint, so that the heating temperature is low, deformation after joining is small, and distortion and The advantage of fewer defects can be enjoyed. Therefore, the number of devices can be significantly reduced, and the number of man-hours for manufacturing operations can be significantly reduced, and workability and quality can be improved.
[0059]
Furthermore, as described above, by temporarily attaching the joint plate 41 with an adhesive, the structure can be simplified and the workability can be improved. In addition, as described above, the steps and the slopes provided at the ends of the joint plates 42 and 43 facilitate the positioning and improve the workability.
[0060]
In the above description, the joining at the time of assembling the vertically arranged structures as shown in FIG. 8 has been described. However, in the case where the hollow structural members are joined in a substantially horizontal state to manufacture the structures. However, as described above, since the joining can be performed from one side without using a special auxiliary device such as a supporting member, the supporting device for the hollow structural member may be as simple as supporting the own weight, Also, there is no need to turn over after joining one side to join the opposite side.
[0061]
From this, simplification of the apparatus and improvement in workability can be achieved even in the case of joining hollow structural members arranged in a substantially horizontal state. The number of parts and assembling man-hours can be reduced, and the production period can be shortened in combination with the improvement of workability. By improving productivity and significantly reducing costs, a robust and lightweight vehicle can be provided at low cost. .
[0062]
Although the present invention has been described as being suitable for manufacturing a structure of a vehicle, it can also be applied to a case in which friction stir welding is performed by butt-joining hollow members forming a structure of an aircraft, a ship, or the like. .
[0063]
【The invention's effect】
The present invention described above has the following effects.
According to the first aspect of the present invention, when manufacturing the structure by joining the hollow structural members to each other, the hollow structural members extend both the one plate and the other plate from the connection portion with the rib plate. Because of the configuration having the portion, the portion can be sandwiched between the rotating surfaces of the bobbin-type friction stir welding rotary tool, and the hollow structural members can be joined to each other using the bobbin-type friction stir welding rotary tool. Therefore, unlike the case of using a probe-type friction stir rotation tool, there is no need for a support member for resisting the force pressing the rotation tool.
[0064]
In addition, since the space between the tips of one plate can be used as the moving space of the rotary tool for friction stir welding, when joining the other plates, the rotary tool for friction stir welding is used from outside the other plate. There is no need to work from the side of one plate, without having to flip the hollow structural profile. The one plate is connected via a flat joint plate, but the joining of the one plate and the joint plate can also be performed from the one plate side, and the joining work of both plates is from the one plate side This simplifies the work and the equipment required for it.
[0065]
According to the invention as set forth in claim 2, when joining the hollow structural members, the joint plates are fitted between the one plates, and the one plates are connected via the joint plates. The fitting plate can be positioned and fixed to the one plate from the front side of one plate, so operation is simple.
[0066]
According to the third aspect of the present invention, when joining the hollow structural members, the joint plates are fitted between the one plates, and the one plates are connected via the joint plates. Because the stepped shape of the tip side surface is dented on the outer surface side, or the end of the joint plate is dented on the side that becomes the inner surface, it is easy to fit the joint plate from the outside of one plate, Positioning and fixing can be easily performed by the steps between the plate and the joint plate. Forming a step on both the one plate and the joint plate provides more stability when fixed.
[0067]
According to the fourth aspect of the invention, when joining the hollow structural members, the plates are connected to each other through the joint plate having an inclined surface on the side surface that matches the inclined surface on the tip side surface of the one plate. Since the tip side surface of the one plate is inclined so as to open from the inner surface to the outer surface of the one plate, the joint plate can be easily fitted from the outside of the one plate, and can be easily positioned and fixed. Since the joining portion between the plate material and the one plate is an inclined surface, a gap is hardly formed, so that a defect is less likely to occur when friction stir welding is performed.
[0068]
According to the fifth aspect of the present invention, when manufacturing the structure by joining the hollow structural members to each other, the hollow structural members extend beyond the connection portion between the one plate and the other plate with the rib plate. Because of the configuration having the portion, the portion can be sandwiched between the rotating surfaces of the bobbin-type friction stir welding rotary tool, and the hollow structural members can be joined using the bobbin-type friction stir welding rotary tool. Therefore, unlike the case of using a probe-type friction stir rotation tool, there is no need for a jig such as a gantry to withstand the pressing force of the rotation tool, so the operation of preparing and removing the jig is not required, and the manufacturing method is reduced. It's easy.
[0069]
In addition, since the space between the ends of one plate can be used as a moving space for the friction stir welding rotary tool, it is not necessary to use the friction stir welding rotary tool from the outside of the other plate when joining the other plates. You only have to work from the side of one board. The one plate is connected via a flat joint plate, but the joining of the one plate and the joint plate can also be performed from the one plate side, and the joining work of both plates is from the one plate side This simplifies the manufacturing method and the necessary equipment.
[0070]
According to the sixth aspect of the invention, by temporarily fixing the plates with the adhesive, the temporary fixing can be easily and firmly performed. In particular, it is effective when a structural temporary fixing structure is not provided between the plates to be joined.
[0071]
According to the invention described in claim 7, the one plate and the joint plate can be temporarily and easily fixed firmly. Especially effective when the structural temporary fixing structure is not provided between the plates to be joined or even when it is provided, the hollow structural members are arranged vertically and the effect of the structural temporary fixing structure cannot be expected. It is.
[Brief description of the drawings]
FIG. 1 is a sectional view showing a structure manufacturing method and a hollow structural member according to an embodiment of the present invention.
FIG. 2 is a cross-sectional view showing joining with a bobbin tool according to an embodiment of the present invention.
FIG. 3 is a sectional view showing a shape for positioning and fixing plates according to an embodiment of the present invention.
FIG. 4 is a sectional view showing a shape for positioning and fixing plates according to another embodiment of the present invention.
FIG. 5 is a sectional view showing a shape for positioning and fixing plates according to another embodiment of the present invention.
FIG. 6 is a sectional view showing a shape for positioning and fixing plates according to another embodiment of the present invention.
FIG. 7 is a cross-sectional view showing the joining of other plates according to another embodiment of the present invention.
FIG. 8 is a schematic cross-sectional view of a vehicle body according to an embodiment of the present invention during manufacture.
FIG. 9 is a cross-sectional view showing a conventional structure manufacturing method and a hollow structural member.
[Explanation of symbols]
1. Roof structure
2. Side structure
3… Floor structure
11 ... Probe type rotary tool
12 ... shape retention material
13 ... Support member
20 ... Hollow panel
20a ... top plate
20b ... vertical rib
20c ... Bottom plate
21 Joint plate
30 ... Bobbin tool
30a ... pin
30b ... upper shoulder
30c ... lower shoulder
40 ... hollow structural member
40a ... top plate
40b ... lower surface plate
40c ... rib
41 ... Joint plate
42 ... Joint plate (with step)
43 ... Joint plate (with inclination)
44… hollow material
44b ... lower surface plate
44c ... convex part
50 ... hollow structural member
51: Hollow structural member
K: Joint
W… Work
L1, L2: Projection amount of one plate (top plate) from the rib plate
M1, M2: Projection amount of other plate (lower plate) from rib plate
N1, N2... Shortness of the tip of one plate (upper plate) and another plate (lower plate)

Claims

対向する２つの板と前記両板を接続支持する複数のリブ板とからなる中空構造型材において、
前記対向する２つの板は最も端のリブ板との接続部分よりも先端が延出しかつ前記対向する２つの板のうち一の板は他の板よりも先端が短いことを特徴する中空構造型材。In a hollow structural member composed of two opposing plates and a plurality of rib plates that connect and support the two plates,
A hollow structural member characterized in that the two opposing plates have a tip extending beyond a connection portion with the endmost rib plate, and one of the two opposing plates has a tip shorter than the other plate. .

請求項１に記載の中空構造型材において、前記一の板の先端に、継手板と接続できるとともに、前記一の板の外表面側から前記継手板をはめて位置決め固定するための継手形状が形成されていることを特徴する中空構造型材。2. The hollow structural member according to claim 1, wherein a joint shape is formed at a tip of the one plate so that the joint plate can be connected to a joint plate, and is positioned and fixed by fitting the joint plate from an outer surface side of the one plate. 3. A hollow structural member characterized by being made.

請求項２に記載の中空構造型材において、前記継手形状として、前記一の板の先端側面が外表面側に段状となるよう形成されていることを特徴とする中空構造型材。3. The hollow structural member according to claim 2, wherein the joint has a shape in which a front end side surface of the one plate is stepped toward an outer surface side. 4.

請求項２に記載の中空構造型材において、前記継手形状として、前記一の板の先端側面が前記一の板の内表面から外表面に向かって開いた傾斜面に形成されていることを特徴する中空構造型材。3. The hollow structural member according to claim 2, wherein, as the joint shape, a tip side surface of the one plate is formed as an inclined surface that opens from an inner surface to an outer surface of the one plate. 4. Hollow structural members.

対向する２つの板と前記両板を接続支持する複数のリブ板とからなる中空構造型材同士を摩擦接合して構造物を製造する構造物製造方法において、
前記対向する２つの板は最も端のそれぞれのリブ板との接続部分よりも先端が延出しかつ前記対向する２つの板のうち一の板は他の板よりも先端が短い前記中空構造型材となっていて、対向する回転面と前記回転面を繋ぐ回転軸とを先端に有するボビン型摩擦攪拌接合用回転ツールを一の板の先端同士の間隔からなる空間を移動させて他の板同士を摩擦攪拌により接合する工程と、
次に、前記ボビン型摩擦攪拌接合用回転ツールを用いて前記継手板と前記一の板とを摩擦攪拌により接合する工程とからなることを特徴とする構造物製造方法。In a structure manufacturing method for manufacturing a structure by frictionally joining hollow structural members composed of two opposing plates and a plurality of rib plates that connect and support the two plates,
The two opposing plates have a tip extending beyond the connection portion with the respective end rib plates, and one of the two opposing plates has the hollow structural member having a tip shorter than the other plate. A bobbin-type friction stir welding rotary tool having a rotating surface facing the rotating surface and a rotating shaft connecting the rotating surface at a tip is moved in a space formed by a gap between the tips of one plate to separate the other plates. Joining by friction stirring,
And a step of joining the joint plate and the one plate by friction stirring using the bobbin-type friction stir welding rotary tool.

２つの板同士を摩擦接合して構造物を製造する構造物製造方法において、
一方の板と他方の板との少なくとも一方に接着剤を塗布する工程と、
次に、前記一方の板と前記他方の板とを接着剤を塗った箇所で接触させて配置する工程と、
次に、前記一方の板と前記他方の板とを摩擦接合を行うことにより前記板同士を接合させる工程とからなることを特徴とする構造物製造方法。In a structure manufacturing method for manufacturing a structure by frictionally joining two plates together,
A step of applying an adhesive to at least one of the one plate and the other plate,
Next, a step of placing the one plate and the other plate in contact with each other at a location where the adhesive is applied, and
Next, the one plate and the other plate are subjected to friction welding to join the plates to each other, thereby forming a structure.

請求項５に記載の構造物製造方法において、前記継手板と前記一の板とを摩擦攪拌により接合する前に、前記継手板と前記一の板との少なくともいずれか一方に接着剤を塗布する工程を含むことを特徴とする構造物製造方法。The structure manufacturing method according to claim 5, wherein an adhesive is applied to at least one of the joint plate and the one plate before joining the joint plate and the one plate by friction stirring. A method for manufacturing a structure, comprising the steps of: