AU2003255218B2

AU2003255218B2 - Manufacturing method of structural body and structural body

Info

Publication number: AU2003255218B2
Application number: AU2003255218A
Authority: AU
Inventors: Wataru Kawamura; Norihisa Okada; Masaki Yono
Original assignee: Hitachi Ltd
Current assignee: Hitachi Ltd
Priority date: 2000-12-20
Filing date: 2003-10-22
Publication date: 2006-07-13
Anticipated expiration: 2021-11-28
Also published as: AU2003255218A1

Description

Regulation 3.2

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

(ORIGINAL)

Name of Applicant: Actual Inventors: Address for Service: Invention Title: SHitachi, Ltd. of Kanda Surugadai 4-chome, Chiyoda-ku, Tokyo 101-8010, JAPAN Norihisa OKADA Masaki YONO Wataru KAWAMURA DAVIES COLLISON CAVE, Patent Attorneys, of 1 Little Collins Street, Melbourne, Victoria 3000, Australia "Manufacturing method of structural body and structural body" The following statement is a full description of this invention, including the best method of performing it known to us: Q:\OPER\SAS\ul.Dcc 03\12335970-276doc 21/10/03 P kOPERWSEW2I0\hn\I 1235970 rpc doc.07A)616 la- 00 oO CI Manufacturing method of structural body and structural body Background of the Invention The present invention relates to a method of manufacturing one structural body by joining without a gap plural forming products having a flange to an end portion of one plate and another plate, in particular to a manufacture suitable for an end structure for constituting a longitudinal direction end portion of a railway vehicle.

As shown in Japanese Patent No. 2,692,459 (USP No.

5,488,770), a car body of a railway vehicle has a hexahedron body. A longitudinal direction end portion of the railway vehicle is called as an end structure. To the end structure, a passage for coming and going to an adjacent car body is provided.

For this reason, the end structure necessaries two plates for constituting a right side passage and a left side passage and a plate for constituting an upper portion of the passage. Since the three plates join a roof structural body and a side structural body, to the end portion of the outer sides of the three plates have respectively the flanges.

Further, the end portions of the three plates have the reinforcement use flanges.

In the prior art, the forming product having the flange to the end portion of the plate is manufactured by the press manner in which the plate is placed between a female die and a male die. Since the female die and the male die are necessitated and then it becomes the high cost.

For the above reason, to the respective plate L shape plate is welded according to a spot welding manner and one side of L shape plate is formed as the above stated flange.

As a means for lessening the metal die a forming method has proposed as shown in from Fig. 18 to Fig. 20 of Japanese application patent laid-open publication No. Hei 11-310,371. In this method, to the female die an outer peripheral portion of a row material is fixed and the row material is pushed in according a rod shape tool and along to an inner peripheral face of the female die. The tool is moved and the plate is carried out incrementally a buckling processing.

On the other hand, in Japanese application patent laid-open publication No. Hei 10-76,321, a squeezing processing is carried out incrementally.

A construction shown in Fig. 13 will be explained.

To three plates i, 2, 3, after flanges ib, ic, Id, 2b, 2c, 2d, 3b, 3c, 3d have provided. The flanges Ib, 2b of the right and the left plates 1, 2 are overlapped and these flanges la, 2b are carried out according to the spot welding and are formed as one body. The flange is provided as one body by bending the plates 1, 2, 3. Further, the flanges Ic, 3c, 2c are overlapped to a roof structural body and welded.

A reference numeral 4 is a passenger of passengers.

The respective three plates i, 2, 3 are continued to the adjacent flange and a connection portion has a circular arc shape. In this case, to a joining portion between the right and the left plates i, 2, the central plate 3 and the roof structural body 30, a space exists. This space must be closed with another plate to prevent the entering the rain water etc.. The closing working requires the high cost. Further, an outer appearance becomes bad.

Further, the flange is formed by bending the plate, a cross-section thereof has the circular arc shape. For this reason, a groove is provided between the right.-and left plates, accordingly the outer appearance becomes bad.

In the increment forming method, since the metal die is made by one die, the manufacture can be carried out with the low cost. However, in the increment forming method shown in the above stated Japanese application patent laidopen publication Hei 11-310,371, to the end portion the flange is formed but the plate is left on the outer peripheral portion of the flange. In a case where the plate is unnecessary, it is necessary to cut off and remove the outer peripheral portion of the flange.

Further, according to this increment forming.method, when the flange is formed, the angle by making the flange and the bottom plate is not made with the right angle P \OPER\SEWO6Uun\I235970 slpc doc.07A)6A6

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-4c however it works. For example, when a cylinder is joined by S overlapping the flange, the flange has the right angle, it can hardly to carry out the overlapping joining.

00 C 5 Further, it is difficult to form the flange having the In I high height. For this reason, to the flange it is difficult M to overlap another member and a flange of the another member.

On the other hand, according to the processing method shown in the above stated Japanese application patent laidopen publication No. Hei 10-76,321, when the flange is processed, the wrinkle can occur easily in the joining portion between the flange and the flange.

Summary of the Invention It is desirable that when two plates having a flange and a third plate are joined, an occurrence of a space in a joining portion can be prevented.

According to the present invention, there is provided a manufacturing method of a structural body, characterised in that manufacturing a first plate and a second plate for abutting and welding said first plate; said first plate being an extruded frame member and comprising plural ribs along an extrusion direction, a thick portion provided along a side which is an end portion in an orthogonal direction against said extrusion direction, said plural ribs including an end portion rib provided at said end portion, a plate portion except for said end portion rib P:\OPERSEWU26un\I2355971) 5C docO?7A06 -4aof an end portion of said extrusion direction and said thick portion, and a first flange provided by bending said end portion of said plate portion to a side of said end portion 00 rib; C 5 said second plate comprising a third flange provided by In V) bending a first side; c-i Sabutting an end portion in the longitudinal direction of said first flange and an end portion in the longitudinal direction of said third flange; abutting a third side of said second plate which is orthogonal substantially to said second flange to an end portion of said thick portion of said first plate; and welding the respective abutted portions.

The present invention also provides a structural body, characterised in that an extruded frame member and a second plate are welded; said extruded frame member comprises plural ribs along an extrusion direction, a thick portion provided along a side which is an end portion in an orthogonal direction against said extrusion direction, said plural ribs including an end portion rib provided at said end portion, a plate portion except for said end portion rib of an end portion in said extrusion direction and said thick portion, and a first flange provided by bending said end portion of said plate portion to a side of said end portion rib; said second plate comprises a third flange provided by bending a first side; an abutted portion of an end portion in the longitudinal direction of said first flange and an end portion of the longitudinal direction of said third flange is welded; and an abutted portion of a third side of said second plate PAOPER\SEVA2006'h.,12355970 spc doc07/U)6f -4b-

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Swhich is orthogonal substantially to said second flange to an end portion of said thick portion of said first plate is welded.

00 C- 5 The present invention further provides a car body of a In t railway vehicle, characterised in that c-i San end structure of said car body of the railway vehicle comprises a first plate, a second plate, and a third plate; c-i said second plate constitutes a member between an upper portion of a passenger passage and a roof of said car body, and said second plate is welded to said roof; said first plate and said third plate are provided in a right side and a left side, and said first plate and said third plate are welded to said second plate, respectively; said first plate and said third plate constitute a member between said passenger passage and a side face of said car body; said first plate and said third plate are overlapped and welded on said side face of said car body and said roof; said first plate and said third plate are extruded frame members and an extrusion direction of said plates is a vertical direction of said car body; said first plate and said third plate being said extruded frame members comprise plural ribs along an extrusion direction, a thick portion provided along a side which is an end portion in an orthogonal direction against said extrusion direction, said plural ribs including an end portion rib provided at said end portion, a plate portion except for said end portion rib in said end portion in said extrusion direction and said thick portion, and a first flange in which said end portion of said plate portion is bent along to said roof and a side face of said car body; PAOPER\SEW20j6\In\1 2355970 spc dm4)7A06A)6 said second plate comprises a third flange provided by bending a first side; an abutted portion of said end portion in the longitudinal direction of said first flange and said end portion in the longitudinal direction of said third flange is welded; and an abutted portion of said third side being orthogonal substantially to said second flange and said end portion of said thick portion of said first plate is welded.

Brief Description of the Drawings: Fig. 1 body of one is a rear face view of an end structure of a car embodiment according to the present invention; Fig. 2 is II-II cross-section view of Fig. 1; Fig. 3 is III-III cross-section view of Fig. 1; Fig. 4 is an enlarged view of IV portion of Fig. 1; Fig. 5 is V-V cross-sectional view of Fig. 4; Fig. 6 car body of is a perspective view of an end structure of a one embodiment according to the present invention; Fig. 7 is a longitudinal cross-sectional view of an essential portion of an increment forming apparatus; Fig. 8 is a plan view between a flange 52b and a flange 52c in a midway of the forming; Fig. 9 is a plan view of an end portion in a longitudinal direction of a flange in a midway of the forming; Fig. 10 is a plan view of a circular arc portion in a midway of the forming; Fig. 11 is a front face view of an end structure of a car body of another embodiment according to the present invention; Fig. 12 is XII-XII cross-sectional view of Fig. 11; and Fig. 13 is a view corresponding to Fig. 1 in the prior art.

Description of the Invention: A first embodiment of a manufacturing method of a structural body according to the present invention will be explained referring from Fig. 1 to Fig. 12. Fig. 1 shows mainly a left half portion of a car body. The car body comprises a stand flame 10 for constituting a floor, a side structural body 20 for constituting a side face, a roof strucural body 30, and an end structural body 40 for closing an end portion of the car body.

The end structural body 40 comprises a passage 45 for the passengers, a plate 50 for constituting a left side thereof, a plate 60 for constituting a right side thereof, and a plate 70 for constituting an upper portion of the passage The right and the left plates 50 and 60 are substantially quadrangle shape ancV-to an end portion except for a-side of a lower end of the plate flanges 52b, 52c, 52d, 62b, 62c, 62d)are provided. The flange 52b (62b) is the flange in a side of the passage 45. The flange 52c (62c) is the flange which overlaps to the roof structural body 30. The flanges 52d, 52e (62d, 62e) are flanges which overlap to the side structural body To a joining portion of the an upper end of the vertical flange 52b (62b) and the flange 52c (62c) of the upper side, no flange is provided. The flange forms a noncontinuous portion. In this portion, no flange is provided but a portion of a bottom plate 51 (61) is excepted, a quadrangle shape recessed portion 53 (63) is provided. A size of the recessed portion 53 (63) will be described in a latter portion.

The plate 70 for constituting the upper portion of the passage 45 for the passenger is substantially quadrangle shape and has flanges 72b and 72c in the lower side and the upper side. The flange 72c is the flange which overlaps to the roof constructural body End portions of a left side 71b and a right side 71c 8 of the plate 70 are abutted to a bent circular arc shape outer face in which the flange 52b (62b) protrudes from the bottom plate 51 This abutted portion is carried out the welding. The bottom plate 51 (61) of the plate 50 is the same face of a bottom plate 71. Further, this abutting welding is called s as a fillet welding manner.

The right and the left end portions of the flange 72c and the plate in the vicinity of the flange provide raised portions 73, 73 which enter the recessed portion 53 (63) of the plate 50 An abutted portion between the recessed portion 53 (63) of the raised portion 73, 73 is welded. An upper side of the raised portions 73, 73 forms the flange 72c. The flange 52c (62c) and the longitudinal direction end portion of the flange 72c are abutted and welded.

The longitudinal direction end portion of a lower side 72b of the plate 70 is abutted to the flanges 52b, 62b.

and welded. An end portion of the bottom plate 71 between the raised portion 73 and the flange 72b protrudes from the longitudinal direction end portion of the flange 72c.

The abutted portions in above are welded continuously and no water leakage occurs. The welding portions are cut off by a grinding manner and are formed smoothly.

The flange 52e (62e) of the connection portion between the flange 52c (62c) and the flange 52d (62d) forms a circular arc shape.

The protrusion directions of the flanges 52b, 52c, 52d, 52e, 62b, 62c, 62d, 62e, 70b, 70c are orthogonal substantially to the faces of the bottom plates 51, 61, 71.

Accordingly, when the flanges 52c, 52d, 52e, 62c, 62d, 62e, are overlapped to an inner side of the end portions of the side structural body 20 and the roof structural body they overlap in parallel and the good welding can be attained. The lower ends of the right and the left plates 60 are overlapped to the stand frame 10 and are welded.

The plates 50, 60, 70 have a plurality of reinforcement use ribs in the inner side of the car body and in the outer side of the car body but they are not shown in the figure. For example, the rib is formed another member with the plates 50, 60, 70 the spot welding manner is carried out. Further the plates 50, 60, 70 are provided integrally by the plastic processing.

According to the above, to the joining portion between the plate 70, the plate 50 (60) and the roof structural body 30, there is no gap and then the joining is carried out. Further, to the joining portion between the plate 70 and the plate 50 there is no circular arc shape groove of the flange and Xhe good outer appearance can be obtained.

Next, the method for manufacturing the plates 50, and 70 will be explained referring to from Fig. 7 to Fig.

This plate manufacturing method is carried out according to the increment forming method. Fig. 7 shown only a left end portion of the increment forming apparatus.

The other portions have suitably the same construction.

The forming of the plate 50 will be explained. A metal die 120 is a female die (an outer die). The female die 120 is placed horizontally. To an upper face of the female die 120 the plate 50 being the row material is mounted. In an interior portion of the female die 120, a rod shape tool 120 is inserted. The tool 130 descents along to a vertical face of the female die 120 and next moves along to an inner peripheral face of the female die 120. A shape of the inner peripheral face of the female die 120 is the same outer diameter shape of the plate When the tool 130 is carried out to go one round, the tool 130 repeats the above function. Accordingly, -the flat plate 50b being the row material is carried out the squeezing processing. Further, the descendant of the tool 130 means the movement in the squeezing processing direction. This is substantially the movement in an axial direction of the tool 130 and is the movement in a depth direction of the forming product.

A tip end of the tool 130 is flat. A corner portion from the tip end to the side face of the tool 130 has a circular arc shape. The circular arc is a circular arc which is formed by a bottom plate 51 of the plate 50 and the flanges 52b, 52c, 52d. The tool 130 is lifted down rotatively from the movement body (not shown in figure) of the upper portion. The tool 130 moves along to an inner peripheral face (it corresponds to the portions of the flanged 52b, 52c, 52d) of the female die 120.

Since the tool 130 moves by contacting to the row material 50b, the tool 130 rotates (rotates on its axis) as a follower. Accordingly, the tool 130 is not contacted to one point of the row material 50b, a blazing phenomenon can be prevented. Further, a lubricating oil is coated on the upper face of the row material On the upper face of the female die 120, plural positioning use pins (guides) 123 are stood up. When the flat plate of the row material 50b is placed on the upper end of the female die 120, the pin 123 contacts to the outer peripheral portion of the row material 50b....Then the..

positioning is carried out. The upper end (it is called as a shoulder portion) of the inner peripheral side of the female die 120 has a circular arc. This circular-arc exists along the whole periphery of the female die 120.

According to this circular arc, the outer peripheral portion of the row material 50b moves smoothly in the inner peripheral side of the female die 120. Further, the position etc. of the circular arc portion of the shoulder portion of the female die 120 will be described in a latter portion.

The interior portion of the female die 120 has no bottom portion. In the interior portion of the female die 120, a seat 140 for mounting the row material 50b is provided. The seat 140 is supported according to a means 150 which can carry out to control the height position thereof. The seat 140 is provided on a portion which opposes to a tip portion (a lower end) of the tool 130.

The seat 140 is provided on a portion which corresponds to a move track in the peripheral direction of the tool 130.

Namely, the row material 50b is sandwiched by the tip end of the tool 130 and the seat 140. Further, the seat 140 is provided on a central portion of the female die 120.

Accordingly, the central portion of the row material can be fixed.

The seat 140 mounts the row material 50b and fixes it.

The fixing is carried out according to the magnetic force by providing an electromagnet. Or, on an upper face of the seat 140, a vacuum adsorption pad is provided and the fixing is carried out according to a vacuum adsorption. A fixing position is a central portion of the seat 140. The row material 50b is made of a steel system metal, a stainless system metal, and an aluminum alloy system metal.

The means 150 for ascending and descending the seat 140 will be explained. The means 150 is comprised of plural screw mechanisms 151. In Fig. 7, a pair of the screw mechanisms 151 is shown. A seat 145 of a lower end of the seat 140 is supported according to a screw rod 152.

To the seat 145, a rotatable free nut is provided.

According to the rotation of a drive mechanism 155, the screw 152 rotates and the seat 140 descends. Further, between the seat 140 or the seat 145 and a base, plural guides (not shown in figure) for ascending and descending vertically the seat 140 are provided. The means 150 and the female die 120 are installed on the base.

The forming method will be explained. The row material 50b is a flat plate, which is developed as a shape after the forming. In the above stated development, the development size is calculated according to the surface area and the volume of the forming product, similar to the squeezing forming method of the corner portion. Or, it is determined according to the experimentation.

Under the base of the development size, the plate is cut off using a tartlet punch press manner etc.. A connection portion between the flange 52b and the flange 52c is separated. Further, the recessed portion 53 is provided. The development shape of the row material 50b is determined according to the above stated facts.

Next, the row material 50b is mounted on the upper end of the female die 120. In this time, the row material is mounted on the ascended seat 140. The row material is positioning determined by a pin 123.

Next, the row material 50b is fixed to the seat 140.

The fixture position and the fixture means are stated on the former portion.

Next, the seat 140 is descended and next the tool 130 is descended. A descendent position of the tool 130 is a position where between the side face of the tool 130 and the vertical face (the inner peripheral face, the linear portion) of the female die 120 the row material 50b is positioned.

Namely, the row material 50b is sandwiched between the inner peripheral face of the female die 120 and the side face of the tool 130. Under this condition, the tool 130 is descended and as stated in a latter portion the tool 130 is moved in the peripheral direction along to the inner peripheral face of the female die 120. A descendent amount of the tool 130 is one where a tip end of the tool 130 contacts to the descendent row material For example, before the descendent of the seat 140, when the upper face of the seat 140 is positioned at the same face of the upper face (the position where the end portion of the row material 50b is mounted on) of the female die 120, when the tip end of the tool 130 is contacted to the upper face of the row material 50b, the descended amounts of the seat 140 and the tool 130 are the same amount. Both of the seat 140 and the tool 130 can be descended at the same time.

As shown in this embodiment according to the present invention, when the bottom plate 51 is wide and the plate thickness is thin and the central portion of the bottom plate 51 is fixed, since the bottom plate 51 is bent, it is unnecessary to bend the outer peripheral portion of the bottom plate 51 according to the female die 120.

Accordingly, the row material 50b may become to incline.

Further, as stated in a latter portion, when the tool 130 is moved in the peripheral direction, the row material may become to rotate. Accordingly, the row material 50b is fixed to the seat 140.

The descendent position of the tool 130 is a positioned in which between the side face of the tool 130 and the inner peripheral face of the female die 120 the flanges 52b, 52c and 52d are positioned. Further, it is taken into the consideration about the rectangular angle of the flanges 52b, 52c, 52d. When the rectangular angle is taken into the consideration, the tool 130 is positioned to sandwich the row material 50b between the side face of the tool 130 and the inner peripheral face of the female die 120.

Next, the tool 130 is moved along to the inner peripheral face of the female die 120. The tool 130 rotates as a follower. The row material 50b is formed incrementally in accordance with the movement of the tool 130.

Next, every the tool 130 is moved around one periphery, as stated in above, the seat 140 is descended and also the tool 130 is descended. The descendent amounts of the tool and the seat 140 and the descendent position of the tool 130 are the sated in above. Next, the tool 130 is moved along to the inner peripheral face of the female die 120.

Hereinafter, the descendents of the seat 140 and the tool 130 and the movement in the peripheral direction of the tool 130 are repeated. According to the repetition of the above stated process, the outer peripheral portion of 16 the row material 50b is moved in the inner peripheral face of the female die 120. With this, the squeezing processing is carried out. The axial direction of the tool 130 is a squeezing processing direction. The movement direction of the tool 120 along to the inner peripheral face of the female die 120 is a radial direction of the tool 130.

According to this embodiment of the present invention, the row material 50b is deformed in a narrow portion between the female die 120 and the tool 130, since the small and homogeneous strain is given incrementally, the good flat face degree of the bottom plate 51 can be maintained.

In addition to the above, since the flanges 52b, 52c, 52d are formed by restraining extending over the all periphery thereof, the flanges 52b, 52c, 52d are not expanded in the outer side, the forming product having the superior rectangular degree of the flat plate portion and the flange portion can be manufactured.

In particularly to, since the circular arc shape flange of the connection portion between the flange 52c and the flange 52d is made wide to the outer side according to the forming, but since the flanges 52c, 52d are restrained to the outer portion by the female die 120, the vertical flanges 52c, 52d can be formed.

Namely, in the all range from the begin of the squeezing process to the finish process, since the flange is sandwiched between the inner peripheral face of the female die 120 and the side face of the tool 130, the squeezing processing can be carried out by restraining the flanges from the outer portion and from the inner portion.

As a result, the processing having the accuracy with the rectangular degree etc. can be carried out.

As stated in above, in the increment forming using the female die 120, the seat 140 is provided in the inner peripheral side of the female die 120 and to this seat 140 the row material 50b is fixed to, the row material 50b can be fixed to, and a predetermined forming can be attained.

Further, the forming proceeds, the flange is positioned in the vertical face of the female die 120.

Further, the end portion of the female die 120 is moved to direct for the- inner peripheral face of the female die 120 and the squeezing processing is carried out, and further the end portion of the female die 120 is positioned in the inner peripheral face of the female die 120 and the squeezing processing is carried out. Accordingly, the good rectangular degree comprised of the flange and the bottom face 51 can be obtained. Further, the height of the flange can be formed large.

Further, since the end portion of the row material is moved in the female die 120 and the squeezing processing is carried out, when the fatigue of the after forming of the row material 50b is taken into the consideration, after the forming, it is unnecessary to cut off the end portion of the flange.

Since the high load as shown in the press processing is not necessary, the female die 120 can be formed with the easy material such as the general steel material, the thermal treatment such as the sintering and the minute surface finishing such as the press metal die are not necessary.

The movement of the tool 130 will be explained in detail. The plate 50 has the flanges 52b, 52c, 52d in the three sides of the quadrangle shape and another one side no flange is provided. Accordingly, the circular arc portion of the shoulder portion of the female die 120 is provided along to the three sides. Another one side of the row material 50b is not mounted on the another one side of the female die 120. A gap is formed between the both.

The tool 130 moves to direct from the one end side of the flange 52b to the flange 52c and through the flange 52c the tool 130 moves to direct to the end portion of the flange 52d. The move track of the tool 130 in the recessed portion 53 portion is shown in Fig. 7.

In Fig. 8, the tool 130 has moved along to the flange 52d and is passed through the end portion in the longitudinal direction of the flange 52d. Next, the row material 50b is moved reversibly a little to position in the lower portion of the tool 130. Next, the seat 140 and the tool 130 are descended. Next, the tool 130 is moved to reach the end portion in the longitudinal direction of the flange 52b through the flanges 52c, 52e, 52d successively.

After the tool has passed the end portion of the flange 52b, as explained in Fig. 8, the row material 50b is moved reversibly a little to position in the lower portion of the tool 130. Next, the seat 140 and the tool 130 are descended. Next, the tool 130 is moved to reach the end portion in the longitudinal direction of the flange 52d through the flanges 52b, 52e, 52d. Hereinafter, the above stated operation is repeated.

Further, since the flange of the plate 50 is provided only the three sides, the tool 130 is reciprocated as stated in above. The former explanations "the tool 130 is moved in the peripheral direction along to the inner peripheral face of the female die 120" etc, include the case of the three sides. Further, the flange is provided only the three sides, it is unnecessary to reciprocate but it can go around.

After the tool 130 has passed through the end portion in the longitudinal direction of the flanges 52d, 52b, to move the tool 130 the end portion in the longitudinal direction of the flanges 52d, 52b is sandwiched between the side face of the tool 130 and the inner peripheral face of the female die 120 and the end portion in the longitudinal direction of the flanges is formed with a predetermined' shape.

In the midway in the longitudinal direction of the flange when the movement of the tool 130 is stopped, the end portion side from there is not the linear shape.

Between the end portion of the row material 50b having the no flange and the end portion of the female die 120, there is a gap having more than a radius of the tool 130. As the size of the above stated recessed portion 53, it is necessary to have the size through which the tool 130 can be passed.

The connection portion between the flange 52b and the flange 52c is separated. Further the recessed portion 53 is arranged. The distance between the flange 52b and the flange 52c, namely the size of the recessed portion 53 is determined to press the end portion in the longitudinal direction of the flanges 51b, 52c by the side face of the tool 130 to the inner peripheral face of the female die 120.

The tool 130 is moved by pressing the end portion--in the longitudinal direction of the flanges 52b, 52c.

When the tool is moved from the flange 52b to the flange 52c, the lower end of the tool 130 is contacted to the end face of the bottom plate 51, the tool 130 is ascended a little and is moved to the side of the flange 52c and processed and moved in the longitudinal direction of the flange. Namely, the tool 130 is moved as shown in Fig. 8.

The plate 60 is manufactured similarly. The plate is manufactured similarly. The move of the tool 130 in the end portion in the longitudinal direction of the flanges 72b, 72c is carried out similarly.

The processing machine for carrying out the increment forming is a numeric control system processing apparatus, for example NC milling machine or a machining center. To a main shaft of the numeric control system processing apparatus the tool 130 is installed. The tool 130 is moved along to the inner peripheral face of the female die 20 in the vertical direction by the numeric control.

The main shaft having the tool 130 is moved in the vertical direction and in one direction horizontal direction. The female die 120 and the seat 140 are mounted on the table (the base). The table is moved in the horizontal direction of the rectangular direction against the movement direction of the horizontal direction of the main shaft.

According the above stated two movements, the tool 130 is moved along to the inner peripheral face of the female die 120. The ascending and descending means 150 is mounted on the table. In place of the movement in the vertical direction of the tool 130, the table can be ascended and descended.

The example will be explained. The diameter of the tool 130 is 25 mm, the plate thickness of the row material is from 0.5 mm to 4 mm degree, the distance from the inner peripheral face of the female die 120 to the side face of the tool 130 is from 0.8 times to 2 times degree, and the push-in depth of one time of the tool 130 (the descendant amount of one time of the seat 140) is 0.5 time to 2 times of the plate thickness of the row material Further, the height of the flange is 20 mm, the radius of the circular arc (the shoulder portion) of the female die 120 is 5.5-13.5 mm, the diameter of the tool 130 is 25 mm, the radius of the tip end of the tool 130 is from 5.5 mm to 10 mm, and the radius of the circular arc portion 52e is 100 mm.

The size of the row material 50b will be explained.

As shown in Fig. 7, the size of the row material 50b is that the end portion of the row material 50b is positioned in the upper portion of the center of a circular arc R of the shoulder portion of the female die 120 or the end portion of the row material 50b is positioned to the center side of the female die 120 from the upper portion of the above stated center. When the size of the row material is large than the above case, in the circular arc portion 12a of the flange 12, the crack occurs easily in the connection portion between the flange 12 and bottom plate 11.

In the above stated embodiment according to the present invention, after the seat 140 is descended, the tool 130 is descended, however the seat 140 and the tool 130 can be descended at the same time. Further, the tip end of the tool 130 is not formed with the flat shape but can be formed with a sphere shape. Further, the tool can be formed to not rotate.

The squeezing processing can be carried out by fixing the seat 140 and by ascending the female die 120. The tool 130 does not move in the vertical direction in the midway of the forming. The seat 140 is positioned in the position in the axial direction of the tool 130 and is arranged along to the inner peripheral face of the female die 120.

Further, the tool 130 goes around along to the circular arc portion of the shoulder portion of the female die 130, next the tool 130 is moved in the inner peripheral face of the female die 120 and next the tool 130 goes around and after the end portion of the row material is formed with the circular arc shape and the tool 130 is descended along to the inner peripheral face of the female.

die 120, accordingly the height of the flange is made further large.

The embodiment according to the-present invention shown in Fig. 11 and Fig. 12 will be explained. A plate 250 (260) corresponding to the plate 50 (60) is constituted by the extruded frame member. The extruded frame member 250 (260) has plural ribs 255 (265). this extruded frame member 250 (260) is carried out the increment formation.

For this reason, the ribs 255 (265) of the upper end portion and the lower end portion of the extruded frame member 250 (260) -is removed by the cut off.

When the thickness of the plate of the upper end portion and the lower end portion of the extruded frame member 250 (260) and the portion of the side face side of the car body (the portion for providing the flange 252 (262)) is thick and the face of the rib 255 (265) is cut off and then the plate thickness becomes to suit for the increment forming.

To the end portion of the side of the plate 270 and the end portion of the side of the passage 45, the rib 257 (267) is provided. The portion of the end portion 259 of the plate 250 for welding to the end portion of the plate 270 is cut off and the welding use groove is provided.

A protrusion size of the rib 257 (267) is smaller than a protrusion size of the rib 255 (265). A groove 258 is provided to a plate of the rib 257 (267). An end portion 259 of the plate is arranged the side of the passage 45 from an end portion of the side of the passage of the rib 257 (267).

In the groove 258, an end portion of an interior member (not shown in figure) and by the provision of the rib 257 (267) a plate thickness of the end portion of the side of the passage 45 is made thick, as a result the strength corresponding the flange 255 (265) can be secured.

For this reason, the end portion of the side of the passage 45 is not formed with the rib 257 (267) but the plate thickness of the end portion of the passage 45 side can be formed thick. Further, the flange 255 (265) can be provided according to the extrusion processing manner. A thick portion is named generically with the rib 257 (267), the thick plate member and the flange 255 (265).

According to the above stated embodiment of the present invention, it is unnecessary to provide the member by bending the flange corresponding to the flange 52b (62b).

Further, it is unnecessary to provide the recessed portion 53. Accordingly, the plate can be formed easily.

The plate 70 can be formed with the extruded frame member similarly to the plate 250. The extrusion direction of the plate 70 is the width direction of the car body.

The flange 72b is formed in the thick portion of the plate 250 (260). Further, the combination of the plate 220 to the plate 270 can change the combination of the plate 50 to the plate In a case where the plate 250 is not constituted.by one extruded frame member, using plural extruded frame members are welded. This joining (the welding) can be carried out, for example, according to the friction stir welding manner. The plate 270 can be formed with the extruded frame member.

The male die is mounted on the row material and the outer peripheral portion of the row material is bent by the tool along to the outer peripheral portion of the male die and then the flange can be manufactured. Further, the plates 50, 60, 70 can be manufactured according to the press processing manner.

According to the present invention, the two forming products having the flange in the end portion of the plate and the third plate can be welded without the gap (the clearance).

P\OPERISEWU(6VnU235391Osc dwc.7A, -26- SThroughout this specification and claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" or "comprising", will be 00 understood to imply the inclusion of a stated integer or Ci 5 group of integers or steps but not the exclusion of any V) other integer or group of integers.

(Nc The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

Claims

1. A manufacturing method of a structural body, 00 characterised in that (N V 5 manufacturing a first plate and a second plate for In Sabutting and welding said first plate; said first plate being an extruded frame member and comprising plural ribs along an extrusion direction, a thick portion provided along a side which is an end portion in an orthogonal direction against said extrusion direction, said plural ribs including an end portion rib provided at said end portion, a plate portion except for said end portion rib of an end portion of said extrusion direction and said thick portion, and a first flange provided by bending said end portion of said plate portion to a side of said end portion rib; said second plate comprising a third flange provided by bending a first side; abutting an end portion in the longitudinal direction of said first flange and an end portion in the longitudinal direction of said third flange; abutting a third side of said second plate which is orthogonal substantially to said second flange to an end portion of said thick portion of said first plate; and welding the respective abutted portions.

2. A manufacturing method of a structural body according to claim i, characterised in that P %OPER\SEM200)6un\IW235970 spc d.07A66)( -28- ;Z between said end portion in the longitudinal direction r- of said first flange and said end portion in the oo longitudinal direction of said thick portion, manufacturing c- said first plate to which a recessed portion except for said In V) 5 first flange and said plate portion of a side of said thick c-i M portion is provided; manufacturing said second plate having a raised portion in which an end portion in the longitudinal direction of said third flange and a vicinity of said end portion is protruded from said third side; inserting and abutting said raised portion to said recessed portion; and welding said abutted portion.

3. A manufacturing method of a structural body according to claim 2, characterised in that said recessed portion includes a bottom plate of said plate portion of said first plate; and said raised portion includes a portion of a bottom plate of said second plate.

4. A manufacturing method of a structural body according to claim 1, characterised in that said second plate has a fourth flange in which a second side being parallel substantially to said first side of said second plate is bent; an end portion in the longitudinal direction of said fourth flange is abutted to said thick portion of said first P:\OPER\SEM2OU6\Uun\I23559r7O spc docOT7/I6 -29- ;Z plate; and O said abutted portion is welded. 00 A manufacturing method of a structural body In V) 5 according to claim i, characterised in that M said second plate is an extruded frame member and an extrusion direction of said extruded frame member is a longitudinal direction of said third flange; a second side being parallel substantially to said first side of said second plate forms a thick portion; an end portion in the longitudinal direction of a thick portion of said second plate is abutted to said thick portion of said first plate; and said abutted portion is welded.

6. A structural body, characterised in that an extruded frame member and a second plate are welded; said extruded frame member comprises plural ribs along an extrusion direction, a thick portion provided along a side which is an end portion in an orthogonal direction against said extrusion direction, said plural ribs including an end portion rib provided at said end portion, a plate portion except for said end portion rib of an end portion in said extrusion direction and said thick portion, and a first flange provided by bending said end portion of said plate portion to a side of said end portion rib; said second plate comprises a third flange provided by bending a first side; P:\OPER\SEW\2DO6Un\ 1 355970 spc dw-O766 ;Z an abutted portion of an end portion in the r- longitudinal direction of said first flange and an end oo portion of the longitudinal direction of said third flange c- is welded; and In V) 5 an abutted portion of a third side of said second plate c-i M which is orthogonal substantially to said second flange to C- an end portion of said thick portion of said first plate is welded.

7. A structural body according to claim 6, characterised in that between said end portion in the longitudinal direction of said first flange and said end portion in the longitudinal direction of said thick portion, said extruded frame member has a recessed portion except for said first flange and a side of said plate portion of said thick portion; said second plate has a raised portion in which an end portion in the longitudinal direction of said third flange and a vicinity of said end portion is protruded from a third side; said raised portion is inserted to said recessed portion; and said abutted portion is welded.

8. A structural body according to claim 7, characterised in that said recessed portion includes a bottom plate of said PK:OPERMEW D~.Un',12355970 sp dc.07A)66 -31- ;Z plate portion of said extruded frame member; and o said raised portion includes a portion corresponding to 00 a portion of said bottom plate. V) 5 9. A structural body according to claim 6, M characterised in that to said second plate a fourth flange in which a second side being parallel substantially to said first side of said first plate is provided; and an end portion in a longitudinal direction of said fourth flange is welded to said thick portion of said first plate. A structural body according to claim 6, characterised in that said second plate is an extruded frame member and an extrusion direction of said extruded frame member is a longitudinal direction of said third flange; a second side being parallel substantially to said first side of said second plate forms a thick portion; and an end portion in the longitudinal direction of a thick portion of said second plate is welded to said thick portion of said extruded frame member.

11. A car body of a railway vehicle, characterised in that an end structure of said car body of the railway vehicle comprises a first plate, a second plate, and a third PAOPMSE-106U.123597 vcdoc.O7%ft -32- ;Z plate; 0 said second plate constitutes a member between an upper OO portion of a passenger passage and a roof of said car body, and said second plate is welded to said roof; Vt 5 said first plate and said third plate are provided in a right side and a left side, and said first plate and said third plate are welded to said second plate, respectively; said first plate and said third plate constitute a member between said passenger passage and a side face of said car body; said first plate and said third plate are overlapped and welded on said side face of said car body and said roof; said first plate and said third plate are extruded frame members and an extrusion direction of said plates is a vertical direction of said car body; said first plate and said third plate being said extruded frame members comprise plural ribs along an extrusion direction, a thick portion provided along a side which is an end portion in an orthogonal direction against said extrusion direction, said plural ribs including an end portion rib provided at said end portion, a plate portion except for said end portion rib in said end portion in said extrusion direction and said thick portion, and a first flange in which said end portion of said plate portion is bent along to said roof and a side face of said car body; said second plate comprises a third flange provided by bending a first side; an abutted portion of said end portion in the P\OPER\SEW~U(X)O6JUn\I235597U do-O?7AXA)6 -33- ;Z longitudinal direction of said first flange and said end O portion in the longitudinal direction of said third flange is welded; and OO an abutted portion of said third side being orthogonal In substantially to said second flange and said end portion of Ssaid thick portion of said first plate is welded.

12. A car body of a railway vehicle according to claim 11, characterised in that between an end portion in a longitudinal direction of said first flange and an end portion in a longitudinal direction of said thick portion, said frame member has a recessed portion except for said first flange and said plate portion except for said first flange and said plate portion of a side of said thick portion; said second plate has a raised portion which protrudes an end portion in a longitudinal direction of said third flange and a vicinity of said end portion from a third side; said raised portion is inserted to said recessed portion; and an abutted portion is welded.

13. A car body of a railway vehicle according to claim 12, characterised in that said recessed portion includes a portion of a bottom plate of said plate portion of said extruded frame member; and said raised portion includes a portion corresponding to PAOPERISEVN(6'W %I 2355970 pc d.O7AM06 -34- ;Z a portion of a bottom plate.

14. A car body of a railway vehicle according to claim OO C 11, characterised in that In V 5 to said second plate a fourth flange in which a second Sside being parallel substantially to said first side of said O first plate is provided; and an end portion in a longitudinal direction of said fourth flange is welded to said thick portion of said extruded frame member. A car body of a railway vehicle according to claim 11, characterised in that said second plate is an extruded frame member and an extrusion direction of said extruded frame member is a longitudinal direction of said third flange; a second side being parallel substantially to said first side of said second plate forms a thick portion; and an end portion in the longitudinal direction of a thick portion of said second plate is welded to said thick portion of said extruded frame member.

16. A method of manufacturing a structural body substantially as hereinbefore described with reference to Figures 1 to 12.

17. A structural body substantially as hereinbefore described with reference to Figures 1 to 12. P XOPEMEYA2006lVJun 2355970 spc doa)7/06106 0 (N specification and/or claims of this application,

18. A raindividually or collectivehcle body substand all combinationsntially as of ahereinbefy two ore desribed with reference to Figures 1 to 12. DATED this 6 th day of June, 2006 In Hitachi9. The steps, features, compositions and compounds DAVIES COLLISON CAVE S~Patdisclosed herein or referred to or indicated in theapplicant(s) cq specification and/or claims of this application, individually or collectively, and any and all combinations of any two or more of said steps or features. DATED this 6 th day of June, 2006 Hitachi, Ltd. DAVIES COLLISON CAVE Patent Attorneys for the applicant(s)