JP4298784B1 - Method for manufacturing railway vehicle structure by friction stir welding - Google Patents

Method for manufacturing railway vehicle structure by friction stir welding Download PDF

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JP4298784B1
JP4298784B1 JP2008233421A JP2008233421A JP4298784B1 JP 4298784 B1 JP4298784 B1 JP 4298784B1 JP 2008233421 A JP2008233421 A JP 2008233421A JP 2008233421 A JP2008233421 A JP 2008233421A JP 4298784 B1 JP4298784 B1 JP 4298784B1
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joint
friction stir
face plate
stir welding
double skin
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JP2010064634A (en
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昌之 林
俊之 須田
慶知 渡邉
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Nippon Sharyo Ltd
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Abstract

【課題】作業の手間を軽減させた摩擦攪拌接合による鉄道車両用構体の製造方法を提供すること。
【解決手段】第1面板11同士及び第2面板12同士でそれぞれ突き合わせた、傾斜面からなる接合端面11m,11n,12m,12nの接合部分について、第1面板11側及び第2面板12側両方の全長にわたって隙間Pが生じないように、ダブルスキンパネル10を幅方向に荷重をかけた状態で固定し、その接合部分を摩擦攪拌接合用工具150の一対の回転体151,152によって挟んで押さえ込み、長手方向に沿って回転移動する攪拌軸153によって摩擦攪拌して接合する摩擦攪拌接合による鉄道車両用構体の製造方法。
【選択図】 図4
A method for manufacturing a structure for a railway vehicle by friction stir welding with reduced labor is provided.
Both the first face plate 11 side and the second face plate 12 side are connected to the joining end faces 11m, 11n, 12m, and 12n made of inclined surfaces that are faced to each other between the first face plates 11 and the second face plates 12. The double skin panel 10 is fixed in a state where a load is applied in the width direction so that the gap P does not occur over the entire length, and the joint portion is sandwiched and pressed by the pair of rotating bodies 151 and 152 of the friction stir welding tool 150. A method of manufacturing a railway vehicle structure by friction stir welding in which friction stir welding is performed by a stirring shaft 153 that rotates and moves along a longitudinal direction.
[Selection] Figure 4

Description

本発明は、ボビンツール型をした摩擦攪拌接合用工具を使用してダブルスキンパネルを接合することにより鉄道車両用構体を製造するための製造方法に関し、特にダブルスキンパネルの面板同士を隙間無しで行う摩擦攪拌接合による鉄道車両用構体の製造方法に関する。   The present invention relates to a manufacturing method for manufacturing a structure for a railway vehicle by joining a double skin panel using a friction stir welding tool of a bobbin tool type, and in particular, there is no gap between face plates of the double skin panel. The present invention relates to a method of manufacturing a railway vehicle structure by friction stir welding.

新幹線車両などのような高速鉄道車両には、押出成形によって形成されたアルミニウム合金からなるダブルスキンパネルが使用され、その一定幅で長尺なダブルスキンパネル同士を接合することによって鉄道車両用構体が構成される。そして、そうした鉄道車両用構体の製造には、幅方向に突き合わせたダブルスキンパネルの面板同士を、摩擦攪拌によって接合する摩擦攪拌接合が利用されている。例えば、下記特許文献1には、図6に示すようにして行うダブルスキンパネルの摩擦攪拌接合についての記載がある(第1従来例)。   Double-skin panels made of aluminum alloy formed by extrusion molding are used for high-speed railway vehicles such as Shinkansen vehicles, and the structure for railway vehicles is formed by joining long double-skin panels with a certain width. Composed. In manufacturing such a structure for a railway vehicle, friction stir welding is used in which the face plates of the double skin panels that are butted in the width direction are joined together by friction stirring. For example, Patent Document 1 below describes a double-skin panel friction stir welding performed as shown in FIG. 6 (first conventional example).

同文献のダブルスキンパネル100A,100Bは、二面の平行な面板101,102と、両面を連結したリブ109によって構成され、端部リブ108から突き出した自由端の接合部111,112が形成されている。摩擦攪拌接合に当たっては、ダブルスキンパネル100A、100Bの両接合部111,112が突き合わされ、面板101,102同士が面一に配置される。そして、摩擦攪拌接合用工具であるボビンツール150を用いて、接合部111,112を一対のショルダで挟み込み、摩擦攪拌による接合が行われる。その際、接合部111,112の接合端面は、突き合わせ方向に直交して形成されており、突き合わせに際してギャップ120が生じることがある。そのため、接合部111,112はギャップ120を埋めることができるように肉厚に形成されている。   The double skin panels 100A and 100B of the same document are constituted by two parallel face plates 101 and 102 and ribs 109 connecting the both sides, and free end joints 111 and 112 protruding from the end ribs 108 are formed. ing. In the friction stir welding, both joint portions 111 and 112 of the double skin panels 100A and 100B are abutted and the face plates 101 and 102 are arranged flush with each other. And using the bobbin tool 150 which is a tool for friction stir welding, the joining parts 111 and 112 are pinched | interposed with a pair of shoulders, and joining by friction stirring is performed. At that time, the joining end surfaces of the joining portions 111 and 112 are formed orthogonal to the abutting direction, and a gap 120 may be generated during the abutting. Therefore, the junctions 111 and 112 are formed thick so that the gap 120 can be filled.

一方、下記特許文献2,3には、接合部の端面を傾斜面にしたダブルスキンパネルの摩擦攪拌接合について記載がある。特許文献2は、継手部分の上部開口を継手板で塞ぐものであって、その継手板を端面の傾斜を利用して蓋のように載せて設置することで、隙間による欠陥を生じ難くさせた摩擦攪拌接合である(第2従来例)。また、特許文献3は、ダブルスキンパネルが、両面板の接合部の接合端面を傾斜させ、一方が他方に嵌り込むように形成されている。そのため、ボビンツールの回転体による挟み込みによって、傾斜した接合端面同士が押し付けられ、両面に隙間が生じていたとしても、その隙間を閉じた摩擦攪拌接合が行われる(第3従来例)。
特許第4052443号公報(図1、段落0023〜0024) 特開2004−243379号公報(図6、段落0047) 特開2007−283379号公報(図8、段落0053〜0057)
On the other hand, Patent Documents 2 and 3 below describe a friction stir welding of a double skin panel in which an end surface of a joint portion is an inclined surface. In Patent Document 2, the upper opening of the joint portion is closed with a joint plate, and the joint plate is placed and installed like a lid using the inclination of the end face, thereby making it difficult for defects due to gaps to occur. Friction stir welding (second conventional example). In Patent Document 3, the double skin panel is formed so that the joint end surface of the joint portion of the double-sided plate is inclined and one is fitted into the other. For this reason, even if the inclined joining end faces are pressed against each other by the pinching by the rotating body of the bobbin tool and a gap is formed on both surfaces, friction stir welding is performed with the gap closed (third conventional example).
Japanese Patent No. 4052443 (FIG. 1, paragraphs 0023 to 0024) Japanese Patent Laying-Open No. 2004-243379 (FIG. 6, paragraph 0047) JP 2007-283379 (FIG. 8, paragraphs 0053 to 0057)

鉄道車両用構体を構成するダブルスキンパネルは、例えば20メートルもの長さを有するため、剛性の低い自由端である接合部は、長手方向に見た場合に、僅かではあるが板厚方向に歪みが生じていることがある。すると、図6に示すようにダブルスキンパネル100A,100Bの両接合部111,112の高さが揃っていない場合があり、そのまま摩擦攪拌接合を行えば仕上げ面に段差が残ってしまう。そこで、従来は、摩擦攪拌接合を行うに際し、20メートルの全長にわたって段差が生じている箇所を探し出し、ハンマーなどでたたいて高さを揃えるといった、煩わしい作業が必要であった。   The double-skin panel that constitutes a railway vehicle structure has a length of, for example, 20 meters. Therefore, the joint, which is a free end having low rigidity, is slightly distorted in the thickness direction when viewed in the longitudinal direction. May have occurred. Then, as shown in FIG. 6, there are cases where the heights of both joints 111 and 112 of the double skin panels 100A and 100B are not uniform, and if the friction stir welding is performed as it is, a step remains on the finished surface. Therefore, conventionally, when performing friction stir welding, it has been necessary to find a place where a step has occurred over the entire length of 20 meters, and hitting with a hammer or the like to align the heights.

一方、第3従来例は、接合端面を傾斜させるダブルスキンパネルについて、接合の際にその接合端面に隙間を生じさせた接合方法が記載されている。すなわち、摩擦攪拌接合する一の面板側の突き合わせの際、他の面板側の接合端面間に隙間が空き、一の面板の熱収縮後もその開口量が適正であるような寸法で形成したダブルスキンパネルの接合方法が記載されている。
これに対して、本発明は、傾斜した接合端面間を有するダブルスキンパネルについて、その接合端面間の隙間を積極的に無くし、接合部の高さを揃える手間を軽減させた摩擦攪拌接合による鉄道車両用構体の製造方法を提供することを目的とする。
On the other hand, the third conventional example describes a joining method in which a gap is generated in the joining end face when joining the double skin panel in which the joining end face is inclined. In other words, when abutting on one face plate side to be friction stir welded, a double gap is formed with dimensions such that there is a gap between the joining end faces on the other face plate side and the opening amount is appropriate even after thermal shrinkage of one face plate. A skin panel joining method is described.
On the other hand, the present invention relates to a double-skin panel having a slanted joint end surface, a rail by friction stir welding that actively eliminates the gap between the joint end surfaces and reduces the labor of aligning the joint height. It aims at providing the manufacturing method of the structure for vehicles.

本発明に係る摩擦攪拌接合による鉄道車両用構体の製造方法は、鉄道車両用構体を構成する所定幅の長尺な一対の第1面板と第2面板とを幅方向に並んだ複数のリブによって連結したダブルスキンパネルが、幅方向端部にあって前記第1及び第2面板とほぼ直交する端部リブから前記第1及び第2面板が延長して突き出した接合部を有し、その接合部の接合端面には、同じ幅方向端部において前記第1及び第2面板とで異なる方向に傾斜した接合端面が形成されたものであって、幅方向に並べた2枚の前記ダブルスキンパネルについて、同方向に傾斜した接合端面同士を突き合わせ、両ダブルスキンパネルの接合部を、ボビンツール型をした摩擦攪拌接合用工具の一対の回転体によって挟み込み、その回転体の間の攪拌軸によって前記接合端面同士を突き合わせた接合部分を長手方向に沿って摩擦攪拌して接合するものであり、前記第1面板同士及び第2面板同士の前記接合部分について、前記ダブルスキンパネルの全長にわたって前記第1面板側及び第2面板側の両方に隙間が生じないようにするため、前記第1面板側及び第2面板側の一方の接合部分に隙間がある場合には、当該一方の接合部分の隙間を無くし、他方の接合部分では前記接合端面同士を滑らせた接合部が面板の板厚方向に変形を生じるように、前記ダブルスキンパネルを幅方向に荷重をかけた状態で固定し、その接合部分を摩擦攪拌接合用工具の一対の回転体によって挟んで押さえ込み、長手方向に沿って回転移動する攪拌軸によって摩擦攪拌して接合する際、前記板厚方向の変形が生じた方の接合部分では、前記摩擦攪拌接合用工具の一対の回転体が、その変形を戻す大きさの荷重で押さえ込むようにしたことを特徴とする。
A method for manufacturing a railway vehicle structure by friction stir welding according to the present invention includes a plurality of ribs in which a pair of long first face plates and second face plates having a predetermined width constituting the railway vehicle structure are arranged in the width direction. The connected double skin panel has a joint portion at the end portion in the width direction, in which the first and second face plates extend and protrude from end ribs that are substantially orthogonal to the first and second face plates. Two double skin panels arranged in the width direction are formed on the joint end face of the portion, and are formed with joint end faces inclined in different directions from the first and second face plates at the same width direction end. The joint end surfaces inclined in the same direction are butted together, and the joint portion of both double skin panels is sandwiched by a pair of rotating bodies of a friction stir welding tool having a bobbin tool type, and the stirring shaft between the rotating bodies Junction end The joined portions that are brought into contact with each other are frictionally agitated and joined along the longitudinal direction, and the joined portions of the first face plates and the second face plates are joined to the first face plate side over the entire length of the double skin panel. In order to prevent a gap on both the second face plate side and the first face plate side and the second face plate side, if there is a gap on the one face portion, the gap on the one face portion is eliminated. In the other joint part, the double skin panel is fixed in a state where a load is applied in the width direction so that the joint part slid between the joint end faces is deformed in the thickness direction of the face plate, and the joint part is rubbed. holding down across the pair of rotating bodies of stir welding tool, when joined with stirring by friction stir shaft rotated moves along the longitudinal direction, the joint portion towards the deformation of the plate thickness direction is generated, A pair of rotating bodies of serial friction stir welding tool, characterized in that as press down with a load of magnitude return the deformation.

本発明によれば、幅方向に荷重をかけてダブルスキンパネルを固定することにより、接合端面の傾斜面による板厚方向の分力によって同方向の歪みを修正するので、従来行っていた煩わしい修正作業を省略することができる。
また、摩擦攪拌接合時に接合部の変形を戻すようにボビンツールで押さえ込むので、仕上げの良い接合を行うことが可能である。
According to the present invention, since the double skin panel is fixed by applying a load in the width direction, the distortion in the same direction is corrected by the component force in the plate thickness direction due to the inclined surface of the joint end surface, so the troublesome correction that has been performed conventionally Work can be omitted.
In addition, since it is pressed down with a bobbin tool so as to return the deformation of the joint at the time of friction stir welding, it is possible to perform joining with a good finish.

次に、本発明に係る摩擦攪拌接合による鉄道車両用構体の製造方法について、その一実施形態を図面を参照しながら以下に説明する。先ず、図1は、鉄道車両構体の一部を示した斜視図である。この鉄道車両用構体80は、側構体81、屋根構体82そして台枠83が周方向に接合され、長手方向端部には妻構体84が接合されて構成される。そうした側構体81や屋根構体82は、例えば所定の幅をもった長尺なダブルスキンパネル10が幅方向(周方向)に突き合わされて接合される。その接合には、隣り合うダブルスキンパネル10の接合端面同士が突き合わされ、車体長さである20〜25mの距離について摩擦攪拌接合が行われる。   Next, an embodiment of a method for manufacturing a railway vehicle structure by friction stir welding according to the present invention will be described below with reference to the drawings. First, FIG. 1 is a perspective view showing a part of a railway vehicle structure. The railcar structure 80 is configured by joining a side structure 81, a roof structure 82, and a frame 83 in the circumferential direction, and a wife structure 84 at the end in the longitudinal direction. For example, the long double skin panel 10 having a predetermined width is abutted in the width direction (circumferential direction) and joined to the side structure 81 and the roof structure 82. For the joining, the joining end faces of the adjacent double skin panels 10 are abutted, and friction stir welding is performed for a distance of 20 to 25 m which is the vehicle body length.

図2は、ダブルスキンパネル10の接合方法について示した斜視図である。ダブルスキンパネル10同士を接合させる摩擦攪拌接合装置は、パネル長さに応じて形成された架台1を有し、その上にはダブルスキンパネル10を当接させる押圧治具2と位置決ブロック3が複数組設けられている。位置決ブロック3は、台形のブロック体であって、垂直面でダブルスキンパネル10を受けるように架台1に固定されている。一方、押圧治具2は、架台1に固定された支持ブロック21、その支持ブロック21に螺合した調節ロッド22及び、その調節ロッド22に連結され、位置決ブロック3に対向した押圧ブロック23によって構成されている。そして、不図示の摩擦攪拌接合装置には、ダブルスキンパネル10の接合線Sに沿って摩擦攪拌を行うボビンツールが設けられている。   FIG. 2 is a perspective view showing a joining method of the double skin panel 10. The friction stir welding apparatus for joining the double skin panels 10 has a gantry 1 formed according to the panel length, and a pressing jig 2 and a positioning block 3 for bringing the double skin panel 10 into contact therewith. A plurality of sets are provided. The positioning block 3 is a trapezoidal block body, and is fixed to the gantry 1 so as to receive the double skin panel 10 in a vertical plane. On the other hand, the pressing jig 2 includes a support block 21 fixed to the gantry 1, an adjustment rod 22 screwed into the support block 21, and a pressing block 23 connected to the adjustment rod 22 and facing the positioning block 3. It is configured. The friction stir welding apparatus (not shown) is provided with a bobbin tool that performs friction stirring along the joining line S of the double skin panel 10.

次に、図3乃至図5は、本実施形態の製造方法によって行うダブルスキンパネル10の接合工程を示した図である。各図は、ダブルスキンパネル10の長手方向端面を示しており、図3は、架台1上に設置した状態を示し、図4は、ダブルスキンパネル10同士の押し付け状態を示し、図5は、摩擦攪拌を実行している状態を示している。   Next, FIG. 3 to FIG. 5 are views showing a joining process of the double skin panel 10 performed by the manufacturing method of the present embodiment. Each figure shows the end surface in the longitudinal direction of the double skin panel 10, FIG. 3 shows a state where the double skin panel 10 is installed on the gantry 1, FIG. 4 shows a pressing state between the double skin panels 10, and FIG. The state which is performing friction stirring is shown.

本実施形態のダブルスキンパネル10は、図2や図3で示すように横置きにした場合に、ほぼ平行になるように第1面板11と第2面板12が一定の距離をとって配置され、その両面板11,12を連結するように幅方向(図面左右方向)に複数並べられたリブ13によって連結されている。ダブルスキンパネル10は、アルミ材の押出し成形によって形成された中空押出形材であり、その押出し方向(図3の図面を貫く方向)がパネルの長手方向であって、それに直交する方向(図3の左右方向)が幅方向である。   In the double skin panel 10 of the present embodiment, the first face plate 11 and the second face plate 12 are arranged at a certain distance so as to be substantially parallel when placed horizontally as shown in FIGS. The two side plates 11 and 12 are connected by a plurality of ribs 13 arranged in the width direction (left and right direction in the drawing) so as to connect the both side plates 11 and 12. The double skin panel 10 is a hollow extruded shape formed by extrusion molding of an aluminum material, and its extrusion direction (direction passing through the drawing of FIG. 3) is the longitudinal direction of the panel, and a direction perpendicular to the direction (FIG. 3). Is the width direction.

第1及び第2面板11,12の間に設けられた複数のリブ13は、隣り合うもの同士が交互に傾きを変えるように傾斜して配置されたものであるが、幅方向両端の端部リブ13aは、第1及び第2面板11,12に対して直交するように配置されている。そして、第1面板11及び第2面板12は、その端部リブ13aから幅方向に突き出し、自由端の接合部11a,11b及び12a,12bが形成されている。ここで、接合部11a,12aは、ダブルスキンパネル10の幅方向右側端部に形成されたものであり、接合部11b,12bは、同じダブルスキンパネル10の幅方向左側端部に形成されたものである。従って、ダブルスキンパネル10の左右両端部には互いが接合可能な継手になっており、これにより幅方向に並べられたダブルスキンパネル10同士が接合できるようになっている。   The plurality of ribs 13 provided between the first and second face plates 11 and 12 are arranged so as to incline so that adjacent ones alternately change the inclination. The ribs 13 a are arranged so as to be orthogonal to the first and second face plates 11 and 12. And the 1st face plate 11 and the 2nd face plate 12 protrude in the width direction from the edge part rib 13a, and joining part 11a, 11b and 12a, 12b of a free end are formed. Here, the joint portions 11a and 12a are formed at the right end of the double skin panel 10 in the width direction, and the joint portions 11b and 12b are formed at the left end of the same double skin panel 10 in the width direction. Is. Accordingly, the left and right end portions of the double skin panel 10 are joints that can be joined to each other, whereby the double skin panels 10 arranged in the width direction can be joined together.

接合部11a,11b,12a,12bは、図5に示すように、ボビンツール150の回転体が入り込むスペースができるようにした端部リブ13aからの突出量である。そして、先端の接合端面は傾斜した傾斜面になっている。すなわち、ダブルスキンパネル10の右側端部にある接合部11a,12aの接合端面11m,12mは、互いが向き合う内側に傾斜し、左側端部にある接合部11b,12bの接合端面11n,12nは、互いが反対を向いた外側に傾斜して形成されている。従って、ダブルスキンパネル10は、接合端面11m,12mへ接合端面11n,12nが入り込んで嵌合するようになっている。   As shown in FIG. 5, the joint portions 11a, 11b, 12a, and 12b are projection amounts from the end ribs 13a that allow a space for the rotating body of the bobbin tool 150 to enter. And the joining end surface of the front-end | tip is an inclined inclined surface. That is, the joint end surfaces 11m and 12m of the joint portions 11a and 12a at the right end of the double skin panel 10 are inclined inwardly facing each other, and the joint end surfaces 11n and 12n of the joint portions 11b and 12b at the left end are , Are formed to be inclined outwardly facing each other. Accordingly, the double skin panel 10 is configured such that the joint end faces 11n and 12n enter and fit into the joint end faces 11m and 12m.

本実施形態の製造方法は、こうした鉄道車両用構体を構成するダブルスキンパネル10同士を摩擦攪拌接合によって連結する方法である。ダブルスキンパネル10は、鉄道車両用構体を構成する隣り合うもの同士が図2に示すように架台1上に設置され、一方の端部に位置決ブロック3を当て、他方の端部からは押圧治具2によって荷重を加えた固定が行われる。接合するダブルスキンパネル10は、こうした位置決ブロック3と押圧治具2による固定が20メートルほどの全長にわたって数カ所で行われる。   The manufacturing method of this embodiment is a method of connecting the double skin panels 10 constituting such a railway vehicle structure by friction stir welding. As shown in FIG. 2, the double skin panel 10, which is adjacent to each other constituting the railcar structure, is installed on the gantry 1, the positioning block 3 is applied to one end, and the other end is pressed. Fixing by applying a load by the jig 2 is performed. The double skin panel 10 to be joined is fixed at several places over the entire length of about 20 meters by the positioning block 3 and the pressing jig 2.

このとき、一対のダブルスキンパネル10は、第1面板11の接合部11a,11bと第2面板12の接合部12a,12bとが、接合端面11m,11n同士と接合端面12m,12n同士が突き合わされている。しかし、全ての場合に接合端面同士が綺麗に突き合わされるとは限らず、例えば、図3に示すように、ダブルスキンパネル10の製作誤差によって、第2面板12の接合部12a,12bにおいて、その接合端面12m,12nの間に隙間Pが生じてしまうことがある。そうした場合、背景技術の欄で挙げた第3従来例では隙間を許容する方法がとられていたが、本実施形態では、その隙間Pを無くした状態にまでダブルスキンパネル10同士を押圧治具2によって押さえ付ける方法をとっている。   At this time, in the pair of double skin panels 10, the joint portions 11 a and 11 b of the first face plate 11 and the joint portions 12 a and 12 b of the second face plate 12 protrude from the joint end surfaces 11 m and 11 n and the joint end surfaces 12 m and 12 n. Are combined. However, in all cases, the joining end faces are not always abutted cleanly. For example, as shown in FIG. 3, due to a manufacturing error of the double skin panel 10, in the joining portions 12 a and 12 b of the second face plate 12, A gap P may occur between the joint end faces 12m and 12n. In such a case, in the third conventional example given in the background art section, a method of allowing the gap is taken, but in this embodiment, the double skin panels 10 are pressed to each other until the gap P is eliminated. 2 is used.

そのため、隙間Pを詰めて無くすように、ダブルスキンパネル10が所定の荷重で押圧される。こうした隙間Pは、第1面板11及び第2面板12の両方について、しかもダブルスキンパネル10の全長にわたって無くなるように各押圧治具2による押圧力の調整が行われる。ところで、第1面板11及び第2面板12の両方について、それぞれ隙間を無くすように押さえ付けが行われると、例えば図4に示すように、既に当接している反対側の接合部11a,11bには、その接合端面11m,11nが互いの傾斜面を滑って乗り上げ、矢印で示すように板厚方向(図面上下方向)に変形が生じる。ただし、図3に示す隙間Pや図4に示す接合部11a,11bの変形は、その状態が分かりやすいように誇張して表現したものであって、実際はこれほどの隙間間隔や変形量ではなく、極めて微小である。   Therefore, the double skin panel 10 is pressed with a predetermined load so as to close and eliminate the gap P. The adjustment of the pressing force by each pressing jig 2 is performed so that the gap P is eliminated over both the first face plate 11 and the second face plate 12 over the entire length of the double skin panel 10. By the way, when both the first face plate 11 and the second face plate 12 are pressed so as to eliminate the gaps, for example, as shown in FIG. The joint end surfaces 11m and 11n slide on each other's inclined surfaces, and deformation occurs in the plate thickness direction (vertical direction in the drawing) as indicated by arrows. However, the deformation of the gap P shown in FIG. 3 and the joint portions 11a and 11b shown in FIG. 4 are exaggerated so that the state is easy to understand, and actually the gap interval and the deformation amount are not so much. , Very small.

ダブルスキンパネル10は、20メートルほどの長さを有するため、比較的剛性の低い接合部11a,11b,12a,12bは、長手方向に見た場合に、僅かではあるが板厚方向に歪みが生じていることがある。そのため、接合箇所によっては、接合部11a,11b同士、接合部12a,12b同士で高さが異なることがあるが、本実施形態では前述した押さえ込みによって解消している。すなわち、一方のダブルスキンパネル10の接合端面11n,12nが、他方のダブルスキンパネル10の接合端面11m,12mの内側に入り込む。そのため、こうした接合端面同士の噛み合いの際、幅方向に作用する押圧力が、傾斜した接合端面11m,11n等を介し、接合部11a,11b等に板厚方向の分力となって作用する。   Since the double skin panel 10 has a length of about 20 meters, the joints 11a, 11b, 12a, and 12b having relatively low rigidity are slightly distorted in the thickness direction when viewed in the longitudinal direction. May have occurred. For this reason, depending on the joint location, the joint portions 11a and 11b and the joint portions 12a and 12b may have different heights. That is, the joining end surfaces 11 n and 12 n of one double skin panel 10 enter inside the joining end surfaces 11 m and 12 m of the other double skin panel 10. Therefore, when such joint end surfaces are engaged with each other, the pressing force acting in the width direction acts as a component force in the plate thickness direction on the joint portions 11a and 11b and the like via the inclined joint end surfaces 11m and 11n.

接合部11a,11b,12a,12bは、そもそも第1面板11や第2面板12の延長上に形成されているため、長手方向に見た場合に波打つように生じる歪みを修正すれば、接合端面11m,11nなどの位置も第1面板11や第2面板12の高さに揃うことになる。よって、本実施形態では、ダブルスキンパネル10同士の接合部を幅方向に押圧して突き合わせる。そして、単純に接合端面同士を突き合わせるのではなく、一つは、隙間Pが生じている場合にその隙間Pを無くすことを目的とし、もう一つは、接合端面の斜面による板厚方向の分力によって同方向の歪みを修正することを目的としている。従って、押圧力は、当該二つの目的を達成できる大きさとする。 Since the joint portions 11a, 11b, 12a, and 12b are originally formed on the extensions of the first face plate 11 and the second face plate 12, the joint end face can be corrected by correcting the distortion that occurs when undulating when viewed in the longitudinal direction. Positions such as 11m and 11n are also aligned with the heights of the first face plate 11 and the second face plate 12. Therefore, in this embodiment, the joint part of the double skin panels 10 is pressed and abutted in the width direction. And, instead of simply abutting the joining end faces, one is to eliminate the gap P when the gap P is generated, and the other is in the plate thickness direction due to the slope of the joining end face. The purpose is to correct the distortion in the same direction by the component force. Therefore, the pressing force is set to a size that can achieve the two purposes.

こうした押圧治具2によるダブルスキンパネル10の固定が行われた後は、ボビンツール150による摩擦攪拌接合が実行される。図5には、第1面板11と第2面板12を同時に行うように表現されているが、実際には図2に示すようにダブルスキンパネル10が固定され、そのダブルスキンパネル10に対して第1面板11側の接合が行われ、その後反転して上に位置した第2面板12側の接合が行われる。なお、ダブルスキンパネル10の固定の仕方によっては、図5に示すように第1面板11と第2面板12とを同時に行うようにしても良い。   After the double skin panel 10 is fixed by the pressing jig 2, friction stir welding by the bobbin tool 150 is performed. In FIG. 5, the first face plate 11 and the second face plate 12 are expressed to be performed at the same time, but in actuality, a double skin panel 10 is fixed as shown in FIG. Joining on the first face plate 11 side is performed, and then the second face plate 12 side that is inverted and positioned above is joined. Depending on how the double skin panel 10 is fixed, the first face plate 11 and the second face plate 12 may be simultaneously performed as shown in FIG.

摩擦攪拌接合を行うためのボビンツール150は、第1回転体151と第2回転体152、及びその間に位置する攪拌軸153を備え、モータの駆動によって回転体151,152及び攪拌軸153に回転が与えられるように構成されたものである。第1回転体151と第2回転体152とは、その間隔が調整できるようになっており、所定の荷重をかけて接合部11a,11bなどを挟み込むことができるようになっている。   The bobbin tool 150 for performing friction stir welding includes a first rotating body 151 and a second rotating body 152, and a stirring shaft 153 positioned therebetween, and rotates to the rotating bodies 151 and 152 and the stirring shaft 153 by driving a motor. Is configured to be given. The space | interval of the 1st rotary body 151 and the 2nd rotary body 152 can be adjusted now, and it can pinch | join the junction parts 11a and 11b etc. with a predetermined load.

そこで、ボビンツール150は、図5で示すように、その攪拌軸153が接合端面11m,11nの当接位置(接合部分)に重なるように配置し、第1及び第2回転体151,152によって接合部11a,11bを挟み込む。そして、ボビンツール150は、回転しながら図2に示す接合線Sに沿って移動することで、攪拌軸153が接合端面11m,11nの当接部分を摩擦攪拌させ、その周囲の材料を塑性流動化させる。その際、接合部11a,11bを押さえ込んだ第1及び第2回転体151,152が可塑性ゾーンから材料が失われるのを防いでいる。軟化した材料は塑性流動化して攪拌混練され、攪拌軸153の後方に流れ、その後方で互いに混じり合った可塑性材が摩擦熱を失って急速に冷却固化して接合が完結する。   Therefore, as shown in FIG. 5, the bobbin tool 150 is arranged so that the stirring shaft 153 overlaps the contact position (joint portion) of the joining end faces 11m and 11n, and the first and second rotating bodies 151 and 152 are used. The joint portions 11a and 11b are sandwiched. Then, the bobbin tool 150 moves along the joining line S shown in FIG. 2 while rotating, so that the stirring shaft 153 frictionally stirs the contact portion of the joining end faces 11m and 11n, and the surrounding material is plastically flowed. Make it. At that time, the first and second rotating bodies 151 and 152 holding the joint portions 11a and 11b prevent the material from being lost from the plastic zone. The softened material is plastically fluidized and stirred and kneaded, flows behind the stirring shaft 153, and the plastic materials mixed with each other lose the frictional heat and rapidly cool and solidify to complete the joining.

ところで、ダブルスキンパネル10同士を隙間無く幅方向に押さえ付けるため、図4の第1面板11側に見られるように、接合部11a,11bが互いに矢印で示す方向に乗り上げて変形し、段差部分Dを生じさせてしまうことがある。しかし、そうした段差部分Dの板厚方向の突き出し量は僅かである。そして、摩擦攪拌時には、接合部11a,11bなどを挟み込む第1及び第2回転体151,152は、段差部分Dの変形を戻す大きさの荷重をかけて上下方向から押さえ込んでいる。そのため、接合線Sに沿ってボビンツール150が摩擦攪拌を行う途中、段差部分Dでは、第1及び第2回転体151,152による押さえ込みによって変形が戻されるとともに、摩擦攪拌によって他の部分と攪拌混練されて流れる。そして、接合部11a,11bはそもそも同じ高さにあるため、ボビンツール150が通過した後の接合部に段差が生じることはなく、また余分な材料によるバリなどもほとんどできない。   By the way, in order to hold down the double skin panels 10 in the width direction without gaps, the joint portions 11a and 11b are deformed by climbing on each other in the direction indicated by the arrows as seen on the first face plate 11 side in FIG. D may be generated. However, the protruding amount of the stepped portion D in the thickness direction is small. At the time of friction stirring, the first and second rotating bodies 151 and 152 sandwiching the joint portions 11a and 11b are pressed from above and below with a load large enough to restore the deformation of the stepped portion D. Therefore, while the bobbin tool 150 is performing frictional stirring along the joining line S, the stepped portion D is deformed by being pressed by the first and second rotating bodies 151 and 152 and is stirred with other portions by frictional stirring. Kneaded and flows. Since the joint portions 11a and 11b are at the same height in the first place, there is no step in the joint portion after the bobbin tool 150 has passed, and burrs and the like due to extra material are hardly caused.

第1面板11側の摩擦攪拌接合が完了した後は、そのダブルスキンパネル10が上下反転され、架台1の上に第2面板12側を上にして固定される。そして、ボビンツール150が一対の第1及び第2回転体151,152によって接合部12a,12bを挟み込み、回転しながら接合線Sに沿って移動することで、攪拌軸153が接合端面12m,12nの当接部分を摩擦攪拌して接合させる。そして、この第2面板12側においても、接合部12a,12bが互いに乗り上げていている段差部分Dが存在していても、その段差部分Dを第1及び第2回転体151,152で押さえ込むことにより、当該部分の変形を戻しながら摩擦攪拌接合が行われる。 After the friction stir welding on the first face plate 11 side is completed, the double skin panel 10 is turned upside down and fixed on the gantry 1 with the second face plate 12 side up. The bobbin tool 150 sandwiches the joint portions 12a and 12b with the pair of first and second rotating bodies 151 and 152, and moves along the joint line S while rotating, whereby the stirring shaft 153 is joined to the joint end surfaces 12m and 12n. The abutting portions of the two are joined by friction stirring. Even on the second face plate 12 side, even if there is a stepped portion D where the joint portions 12a and 12b ride on each other, the stepped portion D is pressed by the first and second rotating bodies 151 and 152. Thus, the friction stir welding is performed while returning the deformation of the portion.

本実施形態の摩擦攪拌接合による鉄道車両用構体の製造方法では、ダブルスキンパネル10同士を押圧治具2によって幅方向に所定の荷重で押し付けることにより、隙間Pを無くすとともに、接合端面同士の接合部分に生じている板厚方向の歪みを修正する。従って、材料が隙間Pに流れ込んで接合後に凹みなどを生じさせることなく、仕上がりの良い接合面とすることができる。また、従来は板厚方向の歪みによって生じる段差箇所を探し出し、ハンマーでたたいて修正するという作業が必要であったが、本実施形態によれば、そうした煩わしい作業を省くことが可能になる。
更に、本実施形態によれば、一の面板側の隙間Pをなくすようにダブルスキンパネル10を押し付けると、他の面板側の接合部分に傾斜面を乗り上げた段差部分Dを生じるが、それをボビンツール150で押さえ込むことにより、変形を戻して仕上げの良い接合を行うことが可能である。
In the method for manufacturing a railway vehicle structure by friction stir welding according to the present embodiment, the double skin panels 10 are pressed against each other with a predetermined load in the width direction by the pressing jig 2, thereby eliminating the gap P and joining the joining end faces. Correct the distortion in the thickness direction occurring in the part. Therefore, it is possible to obtain a bonded surface with a good finish without causing the material to flow into the gap P and causing a dent after bonding. Conventionally, it has been necessary to search for a stepped portion caused by distortion in the thickness direction and correct it by striking it with a hammer. However, according to the present embodiment, such troublesome work can be omitted.
Furthermore, according to the present embodiment, when the double skin panel 10 is pressed so as to eliminate the gap P on the one face plate side, a stepped portion D is formed in which a sloped surface is ridden on the joint portion on the other face plate side. By pressing down with the bobbin tool 150, it is possible to return the deformation and perform bonding with good finish.

以上、本発明に係る摩擦攪拌接合による鉄道車両用構体の製造方法について一実施形態を説明したが、本発明はこれに限定されることなく、その趣旨を逸脱しない範囲で様々な変更が可能である。
前記実施形態では第1及び第2面板11,12が平面のダブルスキンパネル10を例に挙げて説明したが、ダブルスキンパネル10は、例えば屋根構体を構成する湾曲したもの同士、或いは湾曲したものと平面のものとの接合でもよい。
As mentioned above, although one embodiment was described about the manufacturing method of the structure for rail vehicles by the friction stir welding concerning the present invention, the present invention is not limited to this, but various changes are possible in the range which does not deviate from the meaning. is there.
In the above-described embodiment, the first and second face plates 11 and 12 have been described by taking the double skin panel 10 as an example, but the double skin panel 10 is, for example, curved ones constituting a roof structure or curved ones. May be joined to a flat one.

鉄道車両構体の一部を示した斜視図である。It is the perspective view which showed a part of railway vehicle structure. ダブルスキンパネルの接合方法について示した斜視図である。It is the perspective view shown about the joining method of the double skin panel. ダブルスキンパネルの長手方向端面であって、架台上に設置した状態を示した図である。It is the longitudinal direction end surface of a double skin panel, Comprising: It is the figure which showed the state installed on the mount frame. ダブルスキンパネルの長手方向端面であって、ダブルスキンパネル同士を幅方向に押し付けた状態を示した図である。It is the longitudinal direction end surface of a double skin panel, Comprising: It is the figure which showed the state which pressed the double skin panels in the width direction. ダブルスキンパネルの長手方向端面であって、摩擦攪拌を実行している状態を示した図である。It is the figure which showed the state which is a longitudinal direction end surface of a double skin panel, and is performing friction stirring. 従来のダブルスキンパネルの接合方法について示した図である。It is the figure shown about the joining method of the conventional double skin panel.

符号の説明Explanation of symbols

1 架台
2 押圧治具
3 位置決ブロック
10 ダブルスキンパネル
11 第1面板
12 第2面板
13 リブ
11a,11b,12a,12b 接合部
11m,11n,12m,12n 接合端面
13a 端部リブ
150 ボビンツール
151 第1回転体
152 第2回転体
153 攪拌軸
P 隙間
DESCRIPTION OF SYMBOLS 1 Base 2 Pressing jig 3 Positioning block 10 Double skin panel 11 1st face plate 12 2nd face plate 13 Rib 11a, 11b, 12a, 12b Joint part 11m, 11n, 12m, 12n Joint end surface 13a End part rib 150 Bobbin tool 151 First rotating body 152 Second rotating body 153 Stirring shaft P Clearance

Claims (1)

鉄道車両用構体を構成する所定幅の長尺な一対の第1面板と第2面板とを幅方向に並んだ複数のリブによって連結したダブルスキンパネルが、幅方向端部にあって前記第1及び第2面板とほぼ直交する端部リブから前記第1及び第2面板が延長して突き出した接合部を有し、その接合部の接合端面には、同じ幅方向端部において前記第1及び第2面板とで異なる方向に傾斜した接合端面が形成されたものであって、
幅方向に並べた2枚の前記ダブルスキンパネルについて、同方向に傾斜した接合端面同士を突き合わせ、両ダブルスキンパネルの接合部を、ボビンツール型をした摩擦攪拌接合用工具の一対の回転体によって挟み込み、その回転体の間の攪拌軸によって前記接合端面同士を突き合わせた接合部分を長手方向に沿って摩擦攪拌して接合する、摩擦攪拌接合による鉄道車両用構体の製造方法において、
前記第1面板同士及び第2面板同士の前記接合部分について、前記ダブルスキンパネルの全長にわたって前記第1面板側及び第2面板側の両方に隙間が生じないようにするため、前記第1面板側及び第2面板側の一方の接合部分に隙間がある場合には、当該一方の接合部分の隙間を無くし、他方の接合部分では前記接合端面同士を滑らせた接合部が面板の板厚方向に変形を生じるように、前記ダブルスキンパネルを幅方向に荷重をかけた状態で固定し、
その接合部分を摩擦攪拌接合用工具の一対の回転体によって挟んで押さえ込み、長手方向に沿って回転移動する攪拌軸によって摩擦攪拌して接合する際、前記板厚方向の変形が生じた方の接合部分では、前記摩擦攪拌接合用工具の一対の回転体が、その変形を戻す大きさの荷重で押さえ込むようにしたことを特徴とする摩擦攪拌接合による鉄道車両用構体の製造方法。
A double skin panel in which a pair of long first face plates having a predetermined width and a second face plate constituting a railway vehicle structure are connected by a plurality of ribs arranged in the width direction is disposed at an end in the width direction and the first And the first and second face plates extend and project from end ribs substantially orthogonal to the second face plate, and the joint end faces of the joint portions have the first and second ends at the same widthwise end. A joining end face inclined in a different direction from the second face plate is formed,
For the two double skin panels arranged in the width direction, the joint end surfaces inclined in the same direction are brought into contact with each other, and the joint portions of both double skin panels are formed by a pair of rotating bodies of a friction stir welding tool having a bobbin tool type. In the manufacturing method of a railway vehicle structure by friction stir welding, the joint portion where the joint end surfaces are butted together by the stirring shaft between the rotating bodies is frictionally stirred along the longitudinal direction.
In order to prevent a gap from being formed on both the first face plate side and the second face plate side over the entire length of the double skin panel, the first face plate side of the joint portion between the first face plates and the second face plates When there is a gap in one of the joint portions on the second face plate side, the gap in the one joint portion is eliminated, and the joint portion in which the joint end faces are slid in the other joint portion in the thickness direction of the face plate. Fix the double skin panel with a load applied in the width direction so as to cause deformation,
The joint where the deformation in the plate thickness direction occurs when the joint portion is sandwiched and pressed by a pair of rotating bodies of the friction stir welding tool, and friction stir by the stirring shaft that rotates and moves along the longitudinal direction. In the part, a method for manufacturing a railway vehicle structure by friction stir welding , wherein the pair of rotating bodies of the friction stir welding tool is pressed by a load large enough to restore the deformation .
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