JP2002282970A - Caulking method and apparatus - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a caulking method and a caulking apparatus capable of improving productivity and preventing an air leak from occurring at a joint where a thin sheet and a reinforcing plate, or the thin sheet, the reinforcing plate and a bolt are joined together. SOLUTION: The caulking method includes a process for positioning the bolt 3 at a bolt hole 1a on the thin sheet 1 and a bolt hole 2a on the reinforcing plate 2, both bolt holes being formed throughout the thin sheet 1 and the reinforcing plate 2. The method further includes a bolt caulking process for press- fitting the bolt 3 into the bolt hole to caulk the bolt with the thin sheet and the reinforcing plate, and a reinforcing plate caulking process for caulking the thin sheet and the reinforcing plate. The method has a feature that each caulking process shown above is performed under a fixed relative position of the thin sheet and the reinforcing plate.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a caulking method and a caulking device, and more particularly to a technique for performing caulking at two or more places simultaneously or continuously.

[0002]

2. Description of the Related Art When a bolt is joined to a thin plate member, it is common to join the joint by welding or caulking. In this case, there is a case where a reinforcing plate is stacked and used for the purpose of reinforcing the thin plate member. For example, in a part called a shell constituting an outer shell of the brake booster shown in FIG.
The thin plate member 1 and the reinforcing plate 2 forming the outer shell are welded and joined at a welded portion A. Further, the thin plate member 1, the reinforcing plate 2 and the bolt 3 are also welded at the welded portion B.

[0003]

Conventionally, welding of the thin plate member and the reinforcing plate and welding of the thin plate member, the reinforcing plate and the bolt have been performed by separate devices. In order to improve the productivity, it is desirable that the above-described joining by welding can be simultaneously performed. However, if a large number of parts are welded simultaneously, the welded parts will be deformed due to thermal strain during processing, and residual stress will remain in the processed parts, which may result in airtight leakage. It is difficult to apply to a product that needs to manage the leak of the joint to secure it. In addition, in order to maintain a stable process, it is necessary to strictly control the welding electrodes and the welding conditions such as the surface condition of the parts to be welded, especially oil that adheres before welding. On the contrary, the cost is higher than when each welding step is performed by a separate apparatus, and other construction methods are being studied.

[0004] One of the most effective methods is clamping and fixing by caulking. In this case, after the thin plate member and the reinforcing plate and the bolt are caulked, the reinforcing plate caulking of the thin plate member and the reinforcing plate is performed, and conversely, the reinforcing plate caulking of the thin plate member and the reinforcing plate is performed. After that, the bolt may be caulked with the bolt.

In any case, if the crimped object moves at the time of performing each caulking process, the hole of the bolt caulking or the axis of the bolt is displaced, so that the bolted portion which has been caulked once is unnecessary. Stress works. Therefore, this is a factor that causes a problem of airtight leakage. Of course, when performing the above two different caulking operations at the same time, a problem occurs if the caulked object moves.

[0006] Therefore, an object of the present invention is to make it possible to assemble a caulking so as not to cause the above-mentioned airtight leakage problem.

[0007]

Means for solving the problems The technical means taken to solve the technical problems have conventionally been, as described above, thin sheet members,
Bonding of the reinforcing plate and the bolt by welding was performed separately. Instead of processing by welding, caulking is used to hold the parts so that they do not shift during processing even in the same device so that they are not shifted, and by caulking integrally, a construction method that does not leak air tightly Established. That is, according to the first aspect of the present invention, the thin plate member and the reinforcing plate are installed facing each other so that the bolt hole formed through the thin plate member and the bolt hole formed through the reinforcing plate have the same axis. A setting step of setting the bolt in the mold with the bolt inserted through the bolt hole formed in the thin plate member and the bolt hole formed in the reinforcing plate, and the bolt, the thin plate member and the reinforcing plate A bolt caulking step of caulking and a reinforcing plate caulking step of caulking the thin plate member and the reinforcing plate at a position different from the position of the caulking connection in the bolt caulking step. The reinforcing plate caulking step is a caulking method, wherein the positional relationship between the thin plate member and the reinforcing plate is fixed.

For example, when the pre-process is a bolt caulking process and the post-process is a reinforcing plate caulking process, and the thin plate member and the reinforcing plate are not fixed at the time of the pre-process, the bolt caulking is performed in a state where both bolt hole positions are shifted. Is performed, the bolt is inclined to align with the axis of the bolt hole of the thin plate member and the reinforcing plate, and the thin film member and the reinforcing plate are not caulked in a substantially vertical direction. The bolt is pulled by the bolt, causing displacement. For this reason, there is a possibility that the position of the swage may be displaced at the time of swaging in the subsequent process.

Conversely, when the pre-process is a reinforcing plate caulking process and the post-process is a bolt caulking process, and when the thin plate member and the reinforcing plate are not fixed at the time of the pre-process, the stress at the time of the caulking of the reinforcing plate is used. Unnecessary stress is applied to the bolt inserted into the bolt hole due to the displacement, which may cause an airtight leak failure in a subsequent bolt caulking process.

According to the present invention, in order to cope with the above problems, both the bolt caulking process and the reinforcing plate caulking process are performed in a state where the positional relationship between the thin plate member and the reinforcing plate is fixed. Not only does the influence not affect the caulking in the post-process, but the influence of the caulking in the post-process does not affect the caulking in the preceding process. Therefore, a problem such as airtight leakage does not occur due to unnecessary stress acting due to the influence of caulking in another process.

In the caulking method according to claim 1,
The reinforcing plate caulking of the thin plate member and the reinforcing plate, and the bolt caulking of the thin plate member, the reinforcing plate and the bolt are respectively in the caulking order,
It is not limited whether the caulking is performed from the front or back surface of the thin plate member or the reinforcing plate. Also, each caulking may be performed simultaneously.

According to another aspect of the present invention, there is provided a first base plate, driving means for driving the first base plate in a predetermined direction, and a driving means for driving the first base plate in the predetermined direction. A first mating surface substantially perpendicular to the first mating surface and a first back surface opposite to the first mating surface;
A first die facing the first base plate on the back side of the first die, a first elastic member interposed between the first base plate and the first die, and a second base plate A second mating surface facing the first mating surface and a second back surface opposite to the second mating surface, the second back plate having a second back surface facing the second base plate; A second mold disposed facing the second mold; a second elastic member interposed between the second base plate and the second mold; and a base end fixed to the first base plate. A first caulking means having a distal end portion inserted through a first through hole formed in the first mold from the first back surface to the first mating surface; 2 is fixed to the base plate and the front end portion is connected to the second mating surface from the second back surface. Only the second formed in the second mold
And a second caulking means inserted into the through hole.

According to the second aspect of the present invention, when the first base plate is driven in a predetermined direction by the driving of the driving means, the first base plate is arranged to face the first base plate via the first elastic member. The first die is also driven in a predetermined direction. Since the second mold-matching surface of the second mold faces the first mold-matching surface of the first mold, if this predetermined direction is a direction in which both mold-matching surfaces are brought closer, the driving means is driven. The first mating surface and the second mating surface abut. Therefore, the first
If a material (caulking work) for caulking is set between the mating surface and the second mating surface, these caulking works are sandwiched between the first mold and the second mold. Is fixed. Then, when the first base plate is further driven in a predetermined direction by the driving of the driving means, the elastic force of the first elastic member interposed between the first base plate and the first mold is increased by the driving means. And the first elastic member is elastically deformed, and the relative distance between the first base plate and the first mold decreases (the gap between the first base plate and the first mold). Decreases). The base end of the first caulking means is fixed to the first base plate, and the distal end of the first caulking means has a first mold formed in a first mold from the first back surface to the first mating surface. Since the first through-hole is inserted through the first through-hole, the tip of the first caulking punch jumps out of the first through-hole and protrudes to the first mating surface due to the decrease in the relative distance.
The material set between the first and second mating surfaces is caulked. At this time, since the elastic deformation of the first elastic member applies an elastic force in a direction in which the two mold mating surfaces of the first mold and the second mold come into contact with each other, the caulking work is caused by the first and second molds. The above-mentioned caulking is performed in a state where it is sandwiched between the mold matching surfaces and its position is fixed. Further, when the first base plate is driven in a predetermined direction by the driving of the driving means,
The elastic force of the second elastic member interposed between the second base plate and the second mold also bends to the pressing force from the driving means,
The second elastic member is also elastically deformed, and the relative distance between the second base plate and the second mold decreases (second
The gap between the base plate and the second mold is reduced). The base end of the second caulking means is fixed to the second base plate, and the distal end of the second caulking means is formed in a second mold formed from the second back surface to the second mating surface. 2, the distal end portion of the second caulking means is moved to the second position by the decrease in the relative distance.
Projecting out of the through hole of the first and second mating surfaces,
Then, the material set between the second mating surfaces is caulked. At this time, since the elastic deformation of the first and second elastic members applies an elastic force in a direction in which the two mold mating surfaces of the first mold and the second mold come into contact with each other, the caulking work is formed by the first and second molds. The above-described caulking is performed in a state where the position is fixed by being sandwiched between the second molds.

As described above, by caulking with the caulking device of the present invention, the caulking work is sandwiched between the first and second molds, and the position thereof is fixed. Since the caulking connection and the caulking connection by the second caulking means are performed, the influence of the caulking in the preceding step (caulking by the first caulking means) is reduced by the caulking in the subsequent step (second caulking).
In addition, the influence of the caulking in the subsequent step does not affect the caulking in the preceding step. Therefore, a problem such as airtight leakage does not occur due to unnecessary stress acting due to the influence of caulking in another process.

[0015]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, specific examples of a caulking method and a caulking device according to the present invention will be described with reference to the accompanying drawings.

FIG. 1 is a cross-sectional view of a booster to which the caulking method of this embodiment is applied, FIG. 2 is a cross-sectional view of a main part of the caulking apparatus of this embodiment, and FIGS. It is a figure which shows the effect | action at the time of performing coupling | bonding using a coupling device.

As shown in FIG. 1, the booster has a thin plate member 1 on its surface. A reinforcing plate 2 is attached to the inner surface of the thin plate member 1. This thin plate member 1 and reinforcing plate 2
Are caulked at caulking portion C. Further, a bolt hole 1a of the thin plate member and a bolt hole 2a of the reinforcing plate are formed coaxially with the thin plate member 1 and the reinforcing plate 2, respectively. The bolt 3 is inserted into the bolt holes 1a and 2a, and the caulking portion is formed. D
Is caulked. The caulking connection at the caulking portions C and D in the thin plate member 1, the reinforcing plate 2, and the bolt 3 is shown in FIG.
This is performed by a caulking coupling device shown in FIG.

FIG. 2 is a sectional view of the entire caulking device.
The caulking connection device includes an upper mold 11 and a lower mold 12.

The upper mold 11 includes an upper mold base plate 111 and an upper mold stripper plate 112 separated from the upper mold base plate 111.
The upper die base plate 111 in this example represents the first base plate in the present invention, and the upper die stripper plate represents the first die in the present invention.

The upper base plate 111 has a spring 13
And a reinforcing plate caulking punch 14. The reinforcing plate caulking punch 14 has a base end 14a as shown in FIG.
Are fixed to the upper base plate 111 and the base end 1
The tip 14 b extends downward from the upper base plate 111 and extends downward from the upper base plate 111. The upper base plate 111 is connected to the driving means 20 and can be driven vertically by the driving of the driving means 20.

The upper mold stripper plate 112 is formed in a substantially inverted truncated conical shape so as to abut against the inner surface of the thin plate member 1, and its lower surface is illustrated as an upper mold mating surface 112 a, a surface opposite to the upper mold mating surface 112 a. The upper surface shown in FIG.
b. As can be seen from the figure, the upper mating surface 11
Reference numeral 2a denotes a horizontal surface perpendicular to the vertical direction in which the upper base plate 111 is driven. Further, the upper die stripper plate 112 is disposed to face the upper die base plate 111 on the upper die rear surface 112b side. Inside the upper die stripper plate 112, an upper die rear surface 112 is provided.
The upper die through hole 112c penetrating from the upper die mating surface 112a to the upper die mating surface 112a is formed in the upper die through hole 112c.
The portion protruding from 11 is inserted. Further, a punch 112d for bolt crimping is formed on the upper die mating surface 112a.

The spring 13 has an upper base plate 1 at one end.
The other end is connected to the bottom of the 11 bottomed hole 111a, and the other end is connected to the upper die back surface 112b of the upper die stripper plate 112. Therefore, the spring 13 is connected to the upper base plate 1.
11 and the upper die stripper plate 112. Reference numeral 113 denotes a guide shaft.

The lower die 12 includes a lower die base plate 121 and a lower die stripper plate 122 separated from the lower die base plate 121.
The lower mold base plate 121 in this example represents the second base plate in the present invention, and the lower mold stripper plate 122 represents the second mold in the present invention.

As shown in the figure, the lower die base plate 121 is partially cut out, and the gas cushion 15 is disposed in the cut-out portion. Gas cushion 1
5 comprises a main body 15a filled with gas and a movable part 15b movable by gas pressure and external force. The tip of the movable part 15b is exposed from the upper surface of the lower die base plate 121. I have. The lower die base plate 121 is fixed with a bolt crimping die 16. The bolt crimping die 16 is formed in a cylindrical shape having a bolt setting positioning hole 16c formed therein, and is fixed to the lower mold base plate 121 on the base end 16a side, and extends upward from the base end 16a. The tip 16 b of the lever projects from the lower base plate 121.

The lower die stripper plate 122 has a lower die mating surface 122a and a lower die mating surface 122a
The lower surface in the figure, which is the surface opposite to the above, is the lower die rear surface 122b. As can be seen from the figure, the lower die stripper plate 122 is disposed facing the lower die base plate 121 on the lower die rear surface 122b side.

The lower stripper plate 122 is disposed on the movable portion 15b of the gas cushion 15. Therefore, the movable portion 15b of the gas cushion 15 is formed by the lower die base plate 121 and the lower die stripper plate 1.
22 is interposed.

The lower die stripper plate 122 has a reinforcing plate caulking die 17 fitted therein. The reinforcing plate swaging die 17 is arranged to face the punch so as to be coaxial with the reinforcing plate swaging die 14. further,
The lower die stripper plate 122 has a lower die rear surface 122.
The lower die through-hole 122c penetrating from the lower die mating surface 122a to the lower die through-hole 122c is formed in the lower die through-hole 122c.
The portion protruding from 21 is inserted. The lower die through-hole 122c is formed so as to face coaxially with the bolt caulking punch 112d. The reinforcing plate caulking punch 14 constitutes the first caulking means of the present invention, and the bolt caulking die 16 constitutes the second caulking means of the present invention. Reference numeral 18 denotes a positioning guide shaft.

The caulking operation of the caulking coupling device having the above-described configuration will be described with reference to FIGS.

First, as shown in FIG. 3, a thin plate member 1 is formed on a lower die stripper plate 122 as a caulking work.
The reinforcing plate 2 and the bolt 3 are set (setting step). At this time, the thin plate member 1 and the reinforcing plate 2 are installed facing each other such that the bolt hole 1a formed through the thin plate member 1 and the bolt hole 2a formed through the reinforcing plate 2 have the same axis. The bolt 3 is inserted into a bolt hole 1a formed in the thin plate member 1 and a bolt hole 2a formed in the reinforcing plate 2. In this state, the shaft portion 3e of the bolt 3 is held in the bolt setting positioning hole 16a formed in the bolt crimping die 16.

Next, the driving means 20 is driven to lower the upper base plate 111. Then, the driving force applied to the upper mold base plate 111 is transmitted to the upper mold stripper plate 112 via the spring 13, and the upper mold stripper plate 112 also moves down in conjunction therewith. Then, the upper die mating surface 112a and the lower die mating surface 122a are in contact with each other, the upper die stripper plate 112 holds the bolt head 3b of the bolt 3, and the spring 13 loads the serration portion 3c of the bolt 3 into a thin plate member. 1 and the bolt holes 1a and 2a of the reinforcing plate 2 and press-fit. At this time, the upper base plate 111 and the upper stripper plate 112 are vertically separated by the urging force of the spring 13 as shown in FIG. Further, in this state, as is apparent from the drawing, the reinforcing plate caulking punch 14 is still housed in the upper die stripper plate 112.

When the driving means 20 is further driven to lower the upper base plate 111, the upper base plate 111
The elastic force of the spring 13 interposed between the upper die stripper plate 112 and the upper die stripper plate 112 succumbs to the driving force of the driving means 20,
The spring 13 contracts as shown in FIG. Thereby, the relative distance between the upper die base plate 111 and the upper die stripper plate 112 decreases, and the two come into contact with each other. Along with this, the tip portion 14b of the reinforcing plate caulking punch 14 jumps out of the upper die stripper plate 112 and comes into contact with the reinforcing plate. At this time, since the upper mold mating surface 112a of the upper mold stripper plate 112 and the lower mold mating surface 122a of the lower mold stripper plate 122 are urged by the urging force of the spring 13, the reinforcing plate 2 Thin plate member 1
Is fixed by being sandwiched between the upper stripper plate 112 and the lower stripper plate 122.

The tip of the reinforcing plate caulking punch 14 is further pushed into the reinforcing plate 2 and the thin plate member 1. Then, the reinforcing plate caulking die 17 attached to the lower die stripper plate 122 and the reinforcing plate caulking punch 1
In step 4, the thin plate member 1 and the reinforcing plate 2 are sandwiched, and the swaged portion C of the thin plate member 1 and the reinforcing plate 2 is joined (reinforcing plate swaging step). During this process, since the mold mating surfaces of the upper mold stripper plate 112 and the lower mold stripper plate 122 are urged by the urging force of the spring 13 in a direction in which they contact each other, the reinforcing plate 2 and the thin plate member 1 The state fixed by the upper mold stripper plate 112 and the lower mold stripper plate 122 is maintained. Also, in this state,
A load is applied to the movable portion 15b of the gas cushion 15 from the lower mold stripper plate 122. This load is still smaller than the gas pressure in the main body 15a of the gas cushion 15 and is equal to or less than the withstand load of the gas cushion 15. The movable portion 15b does not move downward, and the movable portion 15b remains exposed from the upper surface of the lower mold base plate 121. Since the movable portion 15b is interposed, the lower mold base plate 121 and the lower mold There is a certain gap between the stripper plate 122.

When the driving means 20 is further driven to lower the upper die base plate 111, the force received by the gas cushion 15 from the lower die stripper plate 122 exceeds the load resistance, and as shown in FIG.
2. The thin plate member 1, the reinforcing plate 2, the bolt 3, and the upper stripper plate 112 are integrally lowered. Due to such integral lowering, the relative distance between the lower die base plate 121 and the lower die stripper plate 122 decreases. With this decrease, the tip 16a of the bolt crimping die 16 abuts the end of the serration portion 3c of the bolt 3 against the bolt crimping die 16. Then, the relative distance between the lower die base plate 121 and the lower die stripper plate 122 is further reduced, and when the two come into contact, the serration portion 3c of the bolt is swaged by the bolt swaging die 16, plastically deformed and expanded. Plastic deformation part 3
The thin plate member 1 and the reinforcing plate 2 are sandwiched and fixed between the plastically deformed portion 3d and the bolt head 3b (bolt caulking step). During this process, since the mating surfaces of the upper and lower die stripper plates 112 and 122 are urged by the urging force of the spring 13 in a direction in which they contact each other, the reinforcing plate 2 and the thin plate member 1 Lower stripper plate 122 and upper stripper plate 11
2 is maintained in a fixed state.

The spring 13 used for the lower mold 12 and the upper mold 11
Instead of the gas cushion 15, a method using cushion rubber, a method of controlling and maintaining hydraulic pressure and air pressure of the press, and the like can be considered.

The thin plate member, the reinforcing plate,
The direction in which the lower and upper dies are installed in the device may be reversed depending on the structure of the die, and the direction in which the parts are installed may also be downward, depending on the type, depending on the type. is there.

As described above, the connection between the thin plate member and the reinforcing plate, and the connection between the serration portion of the bolt and the thin plate member and the reinforcing plate are previously determined by positioning and holding in the mold in the process of processing. Fixation is made. Therefore, the thin plate member, the reinforcing plate, and the bolt do not shift during processing. The bolt caulking step and the reinforcing plate caulking step may be performed in any order. Even when the two caulking steps are performed at the same time, after the bolt is inserted through the bolt hole of the reinforcing plate and the bolt hole of the thin plate member, the bolt is pre-positioned and held in the mold so that the shaft does not shift. If
A similar combination results.

[0037]

As described above, in the present invention,
This method has a great practical effect as a method for preventing airtight leakage of the bolt portion and at the same time greatly improving the productivity as compared with the conventional joining performed by welding.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of a booster to which a caulking method according to an embodiment of the present invention is applied.

FIG. 2 is a cross-sectional view of a main part of the caulking connection device according to the embodiment of the present invention.

FIG. 3 is a diagram showing an operation of the caulking connection device in the embodiment of the present invention.

FIG. 4 is a view showing the operation of the caulking connection device in the embodiment of the present invention, and shows a step following FIG. 3;

FIG. 5 is a view showing the operation of the caulking connection device in the embodiment of the present invention, and shows a step following FIG. 4;

FIG. 6 is a cross-sectional view of a booster to which a conventional welding connection is applied.

[Explanation of symbols]

 1: Thin plate member 1a: Bolt hole of thin plate member 2: Reinforcement plate 2a: Bolt hole of reinforcement plate 3: Bolt 3b: Bolt head 3c: Serration portion of bolt 3d: Plastic deformation portion of bolt 3e: Shaft portion of bolt 11 : Upper die 12: Lower die 13: Spring 14: Punch for reinforcing plate caulking 14 a: Base end of punch for reinforcing plate caulking 14 b: Tip of punch for reinforcing plate caulking 15: Gas cushion 15 a: Body portion of gas cushion 15 b: Gas Movable part of cushion 16: Bolt caulking die 16a: Base end of bolt caulking die 16b: Tip of bolt caulking die 16c: Bolt set positioning hole 17: Reinforcement plate caulking die 18: Guide shaft 20: Driving means 111: Upper die Base plate 111a: Bottom hole of upper die base plate 112: Upper die stripper plate 112a: Upper die mating surface 1 2b: Upper die back surface 112c: Upper die through hole 112d: Bolt caulking punch 113: Guide shaft 121: Lower die base plate 122: Lower die stripper plate 122a: Lower die mating surface 122b: Lower die rear surface 122c: Lower die through hole C: Reinforcing plate caulking part D: Bolt caulking part

Claims (2)

[Claims] 1. The thin plate member and the reinforcing plate are installed so as to face each other such that a bolt hole formed through the thin plate member and a bolt hole formed through the reinforcing plate have the same axis, and A setting step of setting the bolt in the mold with the bolt inserted through the bolt hole formed in the thin plate member and the bolt hole formed in the reinforcing plate; and caulking the bolt with the thin plate member and the reinforcing plate A bolt caulking step of performing the bolt caulking step, and a reinforcing plate caulking step of caulking the thin plate member and the reinforcing plate at a position different from the position of the caulking connection in the bolt caulking step. Is performed in a state where the positional relationship between the thin plate member and the reinforcing plate is fixed. 2. A first base plate, driving means for driving the first base plate in a predetermined direction, a first molding surface substantially perpendicular to the predetermined direction, and a first molding surface. Has a first back surface on the opposite side, a first mold facing the first base plate on the first back side, and interposed between the first base plate and the first mold. A first elastic member, a second base plate, a second molding surface facing the first molding surface, and a second back surface opposite to the second molding surface. The second
A second mold disposed on the back side of the second base plate so as to face the second base plate; and the second base plate and the second mold.
A second elastic member interposed between the first and second molds; a base end portion fixed to the first base plate; and a tip end portion extending from the first back surface to the first mating surface. A first caulking means inserted into a first through hole formed in the first mold, a base end fixed to the second base plate, and a front end fixed to the second base plate from the second back surface; And a second caulking means inserted into a second through hole formed in the second mold over the mold matching surface.