JP2007278393A - Method of manufacturing vibration control valve - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing vibration control panels improving vibration control performance and heat insulating performance and obtaining requested characteristics suitably on these properties. <P>SOLUTION: The method of manufacturing the vibration control panels arranged at spaces facing an object member to suppress diffusion of at least one of vibration and heat from the object member, includes a first process for melting a predetermined Al material and Fe material under decompression to cast a vibration control alloy ingot; a second process for machining the vibration control alloy ingot to form thin plates; a third process for machining the thin plates in corrugated shape; and a fourth process for press-forming the corrugated thin plates to form product shape. The method includes a heat treatment process for heating an object intermediate material to a predetermined temperature and then gradually cooling it in a predetermined temperature change form in one of the second to fourth processes. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention is used for a vibration source that generates vibration and heat, such as an exhaust pipe of an internal combustion engine, as an example. It relates to a manufacturing method.

  An example of an object that generates such vibration is an internal combustion engine. Heat, noise, vibration, and the like are dissipated to the outside from an exhaust system such as an internal combustion engine body and an exhaust manifold (hereinafter abbreviated as exhaust manifold) connected to the internal combustion engine. Conventionally, various covers such as an insulator are used for the vibration source in order to prevent a situation in which the vibration is radiated from the vibration source such as the internal combustion engine body or the exhaust system.

  18 (1) is a perspective view of a typical background art exhaust manifold insulator (hereinafter referred to as an insulator) 1 described in Patent Document 1 below, and FIG. 18 (2) and FIG. It is each sectional drawing seen from each cut surface line AA and CC of 18 (1). Hereinafter, the insulator 1 will be described with reference to FIG.

  The insulator 1 is attached to the exhaust manifold of the internal combustion engine and covers the exhaust manifold. The insulator 1 has a substantially flat front surface portion 1a and a side wall portion 1b that is bent from the front surface portion 1a and extends toward the cylinder head of the internal combustion engine. The insulator 1 is formed by superposing two steel plates 1A and 1B shown in FIG. 18 (2) and FIG. 18 (3), and at one appropriate position of the edge of the slit 2, one of the two steel plates. Is folded at the folded portion 2c with respect to the other steel plate. By this folding, the bonding of the two steel plates 1A and 1B is strengthened.

  The insulator 1 of this background art has a structure in which two steel plates 1A and 1B are overlapped, so that the vibration of the frequency generated from the exhaust manifold through which high-temperature exhaust gas pulsating at a frequency of several thousand times per minute passes. , It acts so as not to be dissipated in the dark.

Another background art is described in Patent Document 2 below. In this background art, as a manufacturing condition for the obtained vibration damping alloy to have the highest vibration damping performance, examination on the annealing temperature and the cooling rate from the annealing treatment was shown, and the alloy material was held at 850 ° C. for 1 hour. Then, by gradually cooling the cooling rate in the temperature range of 850 to 600 ° C. at 5 ° C./min, a material having a crystal grain size of about 500 to 700 μm is obtained. Since such a material has a large internal friction, The vibration control performance is said to be further improved.
JP-A-10-266850 (8th to 11th paragraphs and FIG. 1) JP 2001-059139 A

  In the background art described in Patent Document 2, an invention related to optimization of damping performance is shown. However, when considering commercialization of the material, the desired overall performance is determined from a comprehensive point of view, including various characteristics other than the vibration damping performance of the material, regarding the performance required for the material. It is done. After that, the performance of the material, the manufacturing method, and the manufacturing method of the material into the product are re-evaluated, and a new material satisfying the above desired overall performance is discovered.

  From this point of view, the background art of Patent Document 2 shows improved characteristics in comparison with the background art of Patent Document 2 or earlier with respect to its vibration damping performance. As an example, when used in an insulator for the exhaust manifold, high heat resistance is required, and durability is also required. In these respects, although Patent Document 2 has an explanation regarding optimization of vibration damping performance, there is no explanation or suggestion regarding points such as heat resistance and durability. Therefore, the background art itself described in Patent Document 2 has a problem that it is difficult to use the material as an industrial product such as an automotive part.

  Furthermore, recent internal combustion engines and exhaust manifolds have been made lighter and thinner from the viewpoint of weight reduction. Therefore, the insulator is also required to be lighter and further improved in damping performance. On the other hand, Patent Document 2 does not explain the weight reduction. In this respect, the background art described in Patent Document 2 uses the material as an industrial product such as an automotive part. Has the disadvantage of being difficult.

  In view of these points, as a result of studying the mechanism for realizing the vibration damping action in various covers and materials suitable for the mechanism from various aspects, the present inventor has reached the present invention described later.

  The present invention has been made in order to solve the above-mentioned problems, and its purpose is to improve vibration damping performance and heat insulation performance, and to achieve weight reduction and cost reduction. An object of the present invention is to provide a method for manufacturing a vibration damping panel capable of appropriately obtaining desired characteristics.

  In the following, means for achieving the above object and its operation will be described. According to a first aspect of the present invention, there is provided a method for manufacturing a vibration control panel, wherein a space is provided facing the target member so as to suppress the dissipation of at least one of vibration and heat from the target member that generates at least one of vibration and heat. The vibration damping panel is disposed in a manner that the vibration damping panel is substantially Al and is predetermined to be configured to contain Al: 6 to 10% by weight and the balance Fe. And a first step of casting a damping alloy ingot by melting the Fe material under reduced pressure, a second step of processing the damping alloy ingot to form a thin plate, and a first step of processing the thin plate into a corrugated shape. 3 steps and a fourth step of forming a product shape by pressing a corrugated thin plate, and in any of the second to fourth steps, an intermediate material made of a damping alloy body is determined in advance. The temperature is raised to a heating temperature selected from a plurality of heating temperatures, Characterized in that included slow cooling heat treatment process at a temperature variant selected from pre-defined plurality of temperature variant after.

  When the manufacturing method of the vibration damping panel according to the first aspect of the present invention has the above-described configuration, the following actions are realized in the present invention. In the present invention, as described above, the heating temperature and the slow cooling rate corresponding to the degree of mechanical strength and vibration damping required in the final product are appropriately selected.

  The damping panel manufactured according to the present invention is a ferromagnetic material, and its main vibration damping mechanism is a magnetic / mechanical hysteresis loss associated with irreversible movement of the domain wall. Therefore, the factor that defines the degree of damping of the damping panel of the present invention is considered to be the size of the grain boundary existing in the metal structure of such a polycrystalline material.

  Therefore, in the vibration damping panel of the present invention manufactured as described above, the vibration of the vibration damping cover device can be suppressed by the vibration damping action due to the magnetic and mechanical history loss of the thin plate material itself. Generation of cracks due to vibration of the vibration cover device can be prevented, and the quality of the vibration control cover device can be significantly improved.

  Further, in the manufactured vibration damping panel, the internal distortion of the vibration damping metal material is removed by the above-described heat treatment process, and a vibration damping alloy body having a crystal having a desired average particle diameter is obtained. The average crystal grain size of the damping alloy body can be controlled by the heating temperature, the slow cooling rate, and the like according to the alloy composition.

  According to the present inventors' experiment on the damping alloy body manufactured in this way, such a damping alloy body has a damping performance 7 to 10 times that of structural carbon steel. It has been confirmed that the performance does not decrease from room temperature to around 300 ° C. It has also been confirmed that the strength is comparable to steel materials and the workability is comparable to steel materials. Therefore, it can be processed into a plate shape or a rod shape. It is confirmed that the specific gravity is about 6.8, which is lighter than iron.

  According to a second aspect of the present invention, in the first aspect of the present invention, the thin plate member is formed with a wave shape in which valleys and ridges are repeated alternately along the first direction. A waveform shape in which valleys and ridges are alternately repeated is formed along a second direction intersecting with one direction.

  Since the vibration damping cover device of the present invention has such a configuration, the present invention exhibits the following actions in addition to the actions described above regarding the invention of claim 1. In general, when a metal cover is attached to a vibration source, the vibration damping cover device formed of a thin plate vibrates by transmission of vibration from the vibration source.

  In the present invention, the thin plate material processed into the damping panel is formed with corrugated shapes along the first direction and the second direction, respectively, and the vibration of the damping panel is caused by expansion and contraction of the corrugated portion. It can be significantly suppressed as compared with the case of a flat sheet material. Further, since the corrugated shape is formed in a direction crossing each other with respect to the thin plate material, vibrations in an arbitrary direction of surface vibration of the thin plate material can be absorbed. Thereby, it is possible to suppress the vibration of the vibration control panel together with the vibration suppression effect due to the magnetic and mechanical history loss of the thin plate material itself, and to prevent the occurrence of cracks due to the vibration of the vibration suppression panel. This can greatly improve the quality of the vibration control panel.

  In addition, according to the present invention, such a thin plate material is as good in workability as steel as described above, and is processed into a desired vibration damping cover device shape by pressing the thin plate material. When the corrugated shape expands and contracts, a wide range of processing such as deep drawing is combined with the characteristic that the extension length in processing of the thin plate material formed with the corrugated shape is significantly larger than that of the flat plate shaped thin plate material. Is possible. Thereby, workability is remarkably improved as compared with a thin plate material having a flat plate shape.

  According to the invention of claim 3, in the invention of claim 1 or claim 2, in the heat treatment step, a heating temperature of about 850 ° C. is included as the plurality of predetermined heating temperatures. Features.

  The present invention has the following actions in addition to any of the actions related to the invention described in claim 1 or claim 2. The greater the average crystal grain size of the damping alloy body, the lower the mechanical strength of the damping alloy body. Further, in the vibration damping panel manufacturing method described in relation to the first aspect, the heat treatment step may include a heating temperature of about 850 ° C. as the plurality of predetermined heating temperatures.

  In this case, in addition to the operation according to claim 1 described above, it has a remarkable effect that the corrosion resistance of the manufactured damping panel is remarkably improved. As described above, in the heat treatment step, the damping metal material is heated and then slowly cooled, so that the average grain size of the crystals of the damping alloy body to be produced is large. At this time, when the heating temperature is selected to be about 850 ° C., the level of the average grain size of the crystal depends on the electrical resistance of the vibration-damping alloy body to be manufactured, according to the knowledge from the inventors' experiments and the like. It is considered that the increase in the corrosion resistance of the vibration-damping alloy body is hindered and the movement of ions in the corrosion reaction of the vibration-damping alloy body is hindered.

  Since the vibration damping panel according to the present invention is configured to include the above-described vibration damping alloy body, the vibration damping performance is remarkably improved and the weight can be significantly reduced. In addition, various processes such as deep drawing can be performed in accordance with the shape of the object to be damped, and productivity can be improved. In addition, according to the invention of claim 3, the corrosion resistance of the obtained vibration control panel is remarkably improved, and the effect that the quality can be remarkably improved can be realized.

  Below, it demonstrates along the following embodiment which is the best form for implementing this invention. However, the present invention is not limited to the following embodiments, and includes a wide variety of modifications in the technical field, material, manufacturing method, shape, or structure without departing from the spirit of the present invention.

(First embodiment)
1 to 14 show a first embodiment of the present invention.

  FIG. 1 is a front view of a state in which the metal cover 1 of the first embodiment is mounted on the exhaust manifold 3, FIG. 2 is a cross-sectional view taken along the section line X2-X2 of FIG. 1, and FIG. FIG. 4 is an enlarged front view of the metal cover 1 and FIG. 5 is a cross-sectional view taken along the section line X5-X5 of FIG. 6 is a cross-sectional view taken along section line X6-X6 of FIG. 4, FIG. 7 is a cross-sectional view taken along section line X7-X7 of FIG. 4, and FIG. 8 is a cross-sectional line of FIG. 9 is a cross-sectional view taken along line X8-X8, FIG. 9 is a simplified cross-sectional view taken along section line X9-X9 in FIG. 1, and FIG. 10 is a view for explaining the features of the present embodiment. 11 is a cross-sectional view illustrating the operation of the present embodiment, FIG. 12 is a graph illustrating the vibration damping performance of the present embodiment, and FIG. 13 is the present embodiment. Is a graph showing the micro existing technology damping performance, FIG. 14 is a graph showing the temperature change of the loss factor.

  Hereinafter, with reference to FIG.1 and FIG.2, the outline of the metal cover 1 which is a damping panel is demonstrated. As an example, an exhaust manifold (hereinafter referred to as “exhaust manifold”) 3 of an internal combustion engine such as an automobile engine 2 pulsates at a frequency of several thousand cycles per minute at a high temperature of 600 to 700 ° C. as an example from the combustion chamber of the internal combustion engine. Because the exhaust gas that passes through the exhaust gas passes through, the exhaust manifold 3 itself, which is a target member, also becomes a heat source that generates high-temperature heat radiation. In addition, the explosion sound of fuel in the engine 2, the passage of combustion exhaust gas through the exhaust manifold 3, etc. It becomes a vibration source that dissipates noise caused by noise to the outside. Here, both the engine 2 and the exhaust manifold 3 are the vibration sources of the present invention, but in the following embodiments, the exhaust manifold 3 will be described as an example of the vibration source.

  In this embodiment, in order to suppress such vibration from the exhaust manifold 3 as much as possible, a metal cover 1 having a configuration and a three-dimensional shape, which will be described later, is installed in a manner covering the exhaust manifold 3. The metal cover 1 of the present embodiment is substantially formed from an Fe—Al alloy material (hereinafter referred to as a vibration damping alloy body) described later.

  The present invention has been realized on the basis of knowledge relating to a manufacturing process in which the vibration damping alloy body described in the following embodiments can be employed in a metal cover 1 for automobiles. As an example, a damping metal such as a sandwich steel plate is a known damping material, but a structure such as a sandwich steel plate configured by combining a plurality of types of materials cannot be used for the metal cover 1. This is because the metal cover 1 attached to the exhaust manifold 3 of the automobile becomes a high temperature such as about 600 ° C. as an example, and a relatively large amplitude from the exhaust manifold 3 at a high frequency such as several thousand cycles per minute. This is because the vibration of is transmitted.

  In other words, when sandwich steel plates are used for metal covers, the damping layer made of inorganic fibers, etc., as an example provided in sandwich steel plates, etc. due to the above heat and vibration, etc. will cause thermal destruction and fatigue failure, and will be used. Along with this, it becomes brittle and powders and falls off from the metal cover. As a result, vibration damping and heat shielding properties are lost from the metal cover.

  Further, an Fe—Al alloy material as a vibration damping material is also known as shown in Patent Document 2, but according to existing knowledge about such an Fe—Al alloy material, durability against heat and vibration is known. In other words, there is no knowledge of whether or not a damping alloy material such as an Fe—Al alloy material can be used in severe thermal and vibration environments such as the vicinity of the exhaust manifold 3. Moreover, the knowledge regarding the manufacturing method of the damping metal material like the Fe-Al alloy material which has a longevity name which can be used for a long period of time in such a severe environment is also unknown.

  The present invention has a characteristic that a damping alloy material having damping properties in itself can maintain damping properties and heat shielding properties in a severe thermal and vibration environment where an exhaust manifold cover is installed. In addition, the present invention relates to a method for manufacturing a vibration damping alloy material having a characteristic of high durability that is substantially maintenance-free and maintains quality for several years or more.

  This damping alloy body has an Al content of 6 to 10% by weight, Fe and unavoidable impurities (Si 0.1% by weight or less; Mn 0.1% by weight or less; other C, N, S, O, etc.) And 0.1 wt% or less). Moreover, it manufactures so that it may mention later so that the average particle diameter of the crystal | crystallization of a damping alloy body may exist in the range of 300-700 micrometers. Further, it has been confirmed by the present inventor that the damping alloy body has a specific gravity of about 6.8.

  Such a damping alloy body is a ferromagnetic material, and a vibration damping mechanism can be realized by a magnetic / mechanical hysteresis loss due to irreversible movement of the domain wall by vibration applied from the outside. Thereby, the degree of vibration transmitted to the metal cover 1 is remarkably suppressed. Therefore, the amplitude of vibration in the metal cover 1 can be suppressed. Thereby, due to the vibration of the metal cover 1, it is possible to prevent the problem of increase and damage of metal fatigue in the bent portion of the metal cover 1.

  Hereinafter, the manufacturing method of the metal cover 1 of this embodiment will be described with reference to FIG. In FIG. 3 step a1, intrusion of nitrogen and oxygen is prevented for the Al material and the Fe material that have been adjusted in advance to a ratio in which the Al content and the Fe content in the damping alloy after manufacture are respectively set to predetermined values. Therefore, it melts under a reduced pressure of about 0.1 to 0.01 Pa. Then, in step a2, it pours into a casting_mold | template and the Fe-Al alloy ingot which is a damping alloy body ingot is obtained. Next, in step a3, the obtained alloy ingot is finished into a plastic work material of a predetermined shape, for example, a vibration-damping alloy thin plate, by plastic working such as rolling and forging and machining.

  Next, in step a4 in FIG. 3, the obtained plastic work material is held at a temperature of about 700 to 850 ° C. for about 30 minutes to 2 hours and annealed. The temperature and time during the annealing treatment are appropriately selected from the above ranges in consideration of the alloy composition, the plastic working conditions associated with the shape of the metal cover 1 as the final product, and the like.

  Next, in step a5, the obtained annealed material has a cooling rate in a temperature range from a predetermined holding temperature to 600 degrees as an example, 20 degrees / minute or less (preferably 10 degrees / minute or less, more preferably 1 to 5 degrees). Slow cooling as about 5 degrees / minute). Natural cooling (cooling) may be performed in a temperature range of less than 600 degrees.

  In this way, the internal strain due to plastic working of the damping alloy body is removed, and a damping alloy body having an average crystal grain size of 300 to 700 μm is obtained. The average grain size of the crystal can be controlled by the temperature and time during annealing treatment, the slow cooling rate, etc., according to the alloy composition.

  For example, after holding the plastic working material at a heating temperature of 850 ° C. for 1 hour and then gradually cooling it at a cooling rate in the temperature range of 850 to 600 ° C. at 5 ° / min, a material having a crystal grain size of about 500 to 700 μm Is obtained. Since such a material has a large internal friction, its damping performance is further improved.

  Next, in step a6, the obtained damping alloy body thin plate is processed to have a corrugated shape as described later. Although details of this processing will be described later, the first corrugated shape is formed on the vibration-damping alloy thin plate so that the uneven shape is formed over the entire surface. Next, a second corrugated shape is formed in a direction orthogonal to the direction in which the corrugated projections and depressions are already formed, thereby obtaining a damping panel.

  In step a7, the obtained vibration control panel is subjected to press working including deep drawing and piercing so that a desired three-dimensional shape is formed. Thereby, the metal cover 1 having a three-dimensional shape to be described later is formed.

  Further, even when the lowest natural frequency of the vibration mode of the metal cover 1 matches the resonance frequency of the metal cover 1, in this embodiment, the vibration of the metal cover 1 is significantly suppressed. Due to the resonance, a situation in which a high stress is generated in the metal cover 1 is prevented, and fatigue failure in the metal cover 1 can be prevented. Further, for the same reason, it is possible to prevent the metal cover 1 from generating a large noise due to the resonance.

  Hereinafter, the shape and structure of the metal cover 1 of this embodiment will be further described. As shown in FIG. 2, the metal cover 1 is composed of a thin plate material 4 made of the damping alloy body and having a plate thickness of 0.1 mm. As shown in FIGS. 1, 2, and 9, the exhaust manifold 3 A three-dimensional shape is formed along the external shape. The metal cover 1 includes a side wall T1 and a top T2 that connects the entire periphery of the end of the side wall T1. The side wall T1 and the top part T2 are connected at an obtuse angle θ.

  As an example, the thin plate material 4 used in the metal cover 1 of the present embodiment is formed from a single damping alloy thin plate. As shown in FIGS. 1 to 7, the thin plate member 4 has a shape in which a plurality of corrugated shapes 9 in which ridges 7 and valleys 8 are alternately repeated extend along the first direction A <b> 1. is doing. As shown in FIGS. 3 to 7, the protruding portion 7 has a first rising portion 10 that rises from the valley portion 8 with a height H <b> 1 and a height that is lower than the height H <b> 1. The second upright portions 11 rising with H2 are alternately arranged. Moreover, the said trough part 8 has the flat part 12 and the protrusion 13 alternately arranged as FIG. 3-6 shows.

  As shown in FIG. 4, the first upright portion 10 has a pair of side walls 14 and 15 that rise in an approximately trapezoidal shape at an obtuse angle θ <b> 1 as shown in FIG. 4, and ends of the side walls 14 and 15. 3 includes rising parts 17 and 18 formed extending in the direction of the arrow A1 in FIG. 3 and a recess 16 between the rising parts 17 and 18, respectively.

  On the other hand, the second upright portion 11 is formed by crushing the first upright portion 10 to a predetermined degree as will be described later, and substantially forms an angle θ2 that is an obtuse angle as shown in FIG. A pair of side walls 19, 20 rising in a trapezoidal shape, a pair of folded portions 21, 22 formed by folding the tips of the side walls 19, 20 toward each other, and a recess 23 between the folded portions 21, 22 It is comprised including. The folded portions 21 and 22 are bent so that the folded direction is a direction close to each other. Since the second upright portion 11 is formed by pressing and bending the first upright portion 10, the distance between the valley portion 8 and the turned-up portions 21 and 22 becomes a height H2 lower than the height H1.

  Further, as shown in FIGS. 5 and 6, the protruding portion 13 of the valley portion 8 is such that the base end portions of the side walls 19 and 20 of the second upright portion 11 are opposite to the rising direction of the second upright portion 11. In the direction, a pair of groove portions 24 and 25 each having a substantially arc shape and recessed along the direction of the arrow A1 in FIG. 3 are formed. The groove portions 24 and 25 form a pair of protrusions 26 and 27 on the side opposite to the rising direction of the second upright portion 11 of the thin plate member 4, and the function of the ribs in the metal plate 4 with respect to the bending along the arrow A 2 direction of FIG. Is realized. Further, since the trough 8 is pressed to form the grooves 24 and 25, periodic irregularities are formed along the longitudinal direction thereof as shown in FIG.

  Each of the second upright portions 11 and the protrusions 13 has a broken line shape along a second direction A2 that is a direction substantially orthogonal to the first direction A1 that is a direction in which the plurality of waveform shapes 9 extend. It is formed to be continuous.

  The metal cover 1 has such a shape, and is formed by pressing the thin plate material 4 into a three-dimensional shape along the outer shape of the exhaust manifold 3.

  Hereinafter, with reference to FIG. 10, one of the features of the metal cover 1 of the present embodiment will be described. Since the metal cover 1 of the present embodiment is formed into a three-dimensional shape that conforms to the three-dimensional appearance of the exhaust manifold 3 as described above, the metal cover 1 is bent of the thin plate material 4 as shown in FIG. One or a plurality of ridge line corresponding portions 30 which are parts are formed. In the present embodiment, the thin plate member 4 is arranged such that the first direction A1 that is the longitudinal direction of the corrugated shape 9 is a direction intersecting a main ridge line equivalent portion 30 described later among the plurality of ridge line equivalent portions 30. 5 is pressed into a three-dimensional shape.

  Here, the main ridge line equivalent portion 30 is a bent portion where a relatively large curvature characterizing the overall shape of the metal cover 1 continues. That is, it means a bent portion extending over a relatively long length that substantially determines the external shape of the metal cover 1 among various large and small bent portions formed on the metal cover 1.

  When the metal cover 1 is attached to the exhaust manifold 3, the metal cover 1 is also vibrated by transmission of vibration from the exhaust manifold 3. When the metal cover 1 vibrates due to this vibration, the metal cover 1 vibrates so that the portions of the metal cover 1 on both sides of the main ridge line corresponding portion 30 flutter. If such vibration is left unattended, a portion near the ridge line corresponding portion 30 of the metal cover 1 is subject to metal fatigue due to repeated bending, and cracks are likely to occur.

  On the other hand, in the present embodiment, a direction in which the first direction A1 of the plurality of corrugated shapes 9 formed on the metal cover 1 intersects the main ridge line equivalent portion 30, preferably a direction orthogonal to each other. Therefore, the corrugated shape 9 realizes the action of the rib against the vibration centered on the ridge line corresponding portion 30. Thereby, the vibration of the metal cover 1 can be suppressed, the occurrence of cracks in the metal cover 1 can be prevented, and the quality of the metal cover 1 can be significantly improved.

  Further, with respect to the vibration generated along the extending direction of the ridge line corresponding portion 30 described above, the vibration is intermittently extended along the second direction A2 and is continued along the first direction A1 as shown in FIGS. The second upright portion 11 is also capable of realizing a rib function and suppressing vibration.

  Furthermore, the action of preventing the occurrence of cracks due to the vibration is greatly improved in the present embodiment by suppressing the vibration of the metal cover 1 by the damping action according to the above-described magnetic principle of the damping alloy body. Is done.

  Further, in the present embodiment, as shown in FIG. 9, a flange 28 in which the corrugated shape 9 is fully bent is formed on at least a part of the outer peripheral portion of the metal cover 1. Thereby, when the metal cover 1 vibrates, the flange 28 realizes the function of a rib, the amplitude of vibration of the metal cover 1 can be reduced, and the occurrence of cracks in the metal cover 1 is suppressed. be able to.

  The metal cover 1 is formed by forming the thin plate material 4 so as to form a three-dimensional shape, and the plurality of corrugated shapes 9 formed on the thin plate material 4 are such that the raised portion 7 and the valley portion 8 are in the second direction A2. The heights of the raised portions 7 are periodically changed along the longitudinal direction, that is, the first direction A1. Furthermore, the first direction A1 is defined in a direction orthogonal to the main ridge line equivalent portion 30 of the metal cover 1 constituting a three-dimensional shape.

  Therefore, the corrugated shape 9 realizes the action of the ribs against the vibrations on both sides of the main ridge line equivalent part 30. As a result, the vibration from the exhaust manifold 3 prevents the metal cover 1 from vibrating such that the portions of the metal cover 1 on both sides of the main ridge line corresponding portion 30 flutter, and the metal cover 1 This prevents a situation in which the portion near the ridge line corresponding portion 30 is prone to metal fatigue due to repeated bending and is likely to generate cracks.

  Due to the synergistic effect of the magnetic damping action of the damping alloy body itself and the damping action of the metal cover 1 according to the above-described inventions on various shapes and structures of the metal cover 1, The vibration of the metal cover 1 can be suppressed at each stage, the occurrence of cracks in the metal cover 1 can be prevented, and the quality of the metal cover 1 can be significantly improved.

  Further, the metal cover 1 has a direction in which the plurality of corrugated first directions A1 formed on the metal cover 1 intersect with the bent portion 30 of the vibration-damping cover device shape of the metal cover 1, Since it is preferably determined in the orthogonal direction, the corrugated shape realizes the action of the rib against vibration centered on the bent portion 30. Thereby, the vibration of the metal cover 1 can be suppressed, the occurrence of cracks in the metal cover 1 can be prevented, and the quality of the metal cover 1 can be significantly improved.

  FIG. 11 is a simplified cross-sectional view showing the operation of the metal cover 1 of the present embodiment. Hereinafter, the operation of the metal cover 1 will be described with reference to FIG. As described above, the corrugated shape 9 is formed on the entire surface of the thin plate material 4 constituting the metal cover 1 of the present embodiment, and the laminated portion 45 in which the thin plate materials 4 are overlapped is configured.

  When the metal cover 1 undergoes surface vibration due to the vibration received by the metal cover 1 and generates vibration, such vibration is generated by the raised portion 7 as schematically shown in FIG. And the width L4 of the raised portion 7 including the folded portions 21 and 22 of the raised portion 7 at the standard time when the valley portion 8 is not deformed, the width L5 where the width of the raised portion 7 is larger than the interval L4 at the standard time at the extended portion. become. In the compressed region, the width of the raised portion 7 becomes a width L6 that is smaller than the standard interval L4.

  When the metal cover 1 vibrates, such an expansion / contraction operation occurs in each part over the entire surface of the metal cover 1. In the metal cover 1 of the present embodiment, the vibration applied from the outside is caused by the elastic deformation of the thin plate material 4 itself due to the expansion and contraction operation described above occurring in each of the raised portions 7 and the valley portions 8 on the entire surface of the metal cover 1. A considerable part is converted into heat energy by. Thereby, the vibration of the metal cover 1 can be suppressed.

  In addition, in the case where a vibration that causes the metal cover 1 to flutter as a whole is generated by a relatively low frequency band component of the vibration received by the metal cover 1, such an example of an operation is shown in FIG. As shown in the figure, the width of the recess 46 in the extended portion 7 is a width L5 when extended, which is larger than the width L4, compared to the width L4 of the recess 46 of the standard raised portion 7 where the raised portion 7 is not deformed. In the compression portion, the width of the recess 46 is a compression width L6 smaller than the width L4.

  In addition, the inventor measured the length of one cycle of the waveform shape 9 (hereinafter, the cycle length) according to the bending of the waveform shape 9. In contrast to the period length L0 (11 mm in this example) in the standard state in which neither the extension displacement nor the compression displacement is performed, the period length L1 at the time of extension is about 17 mm, which is relative to the period length L0 in the standard state. Thus, an extension allowance of about 55% can be realized.

  Many metal products manufactured by pressing, such as automobile parts, are made of iron or stainless steel. These iron materials and stainless steel materials are frequently used in terms of relatively high strength. On the other hand, in the present embodiment, the thin plate material 4 made of the damping alloy body has a workability equivalent to about 55% ductility and malleability by the above-described wave shape processing, and further, the damping alloy body itself Workability is further improved by ductility and malleability. That is, even when performing press working including deep drawing, it was confirmed that it has workability equal to or higher than that of conventional iron materials. As a result, it can be confirmed that the vibration damping alloy body can be used as the material of the metal cover 1, and in addition to the improvement of the vibration damping performance, the metal cover 1 with improved weight reduction and workability is obtained. Can be realized.

  When processing such a thin plate material 4 by, for example, pressing into a three-dimensional shape required for the metal cover 1, the laminating portion 45 expands and contracts as shown in FIG. The extension allowance in the processing of the thin plate material 4 formed with is significantly larger than that of the flat plate-shaped thin plate material. Thereby, processing becomes markedly easier as compared with a flat plate-shaped thin plate material. This effect can be realized remarkably when a damping alloy body having a relatively low hardness is used as the thin plate material, for example, iron or stainless steel.

  Furthermore, in the present embodiment, as described above, since undesired deformation and cracking of the metal cover 1 are prevented, the plate of the thin plate material 4 constituting the metal cover 1 is achieved in order to achieve this. The necessity of increasing the rigidity of the metal cover 1 or increasing the support location for the exhaust manifold 2 of the metal cover 1 by increasing the thickness or adding a reinforcing member is eliminated.

  This increases the possibility of cracking in the vicinity of the support location due to the increase in the weight of the metal cover 1 assumed when the rigidity of the metal cover 1 is increased, and increases the support location of the metal cover 1. It is possible to prevent the occurrence of cracks due to thermal strain assumed when In these respects, the reliability of the metal cover 1 is significantly improved.

  FIG. 12 is a graph for explaining the vibration damping action of the metal cover 1. Hereinafter, the vibration damping action of the metal cover 1 will be described with reference to FIG. In order to confirm the vibration damping action of the metal cover 1 of the present embodiment, the inventor applies vibrations to the steel plate, the stainless steel plate, the FRP plate, the sandwich steel plate, and the metal cover 1 of the present embodiment. The damping coefficient of vibration was measured. The result is shown in the graph of FIG.

  According to this measurement, the vibration attenuation coefficient of the metal cover 1 of the present embodiment indicated by a region P in FIG. 12 is higher than that of any of a steel plate, a stainless steel plate, and a sandwich steel plate except for an FRP (fiber reinforced plastic) plate. It was confirmed to belong to a large range. Therefore, it has a larger vibration damping coefficient than any of sandwich steel plates having a laminated structure of different materials, FRP containing inorganic fibers inside, steel plates often used as materials for covers of internal combustion engines, stainless steel plates, etc. As a result, it was confirmed that the damping performance was significantly improved compared to the background art.

  FIG. 13 shows the metal cover 1 of this embodiment, a sandwich steel plate using a single-layer aluminized steel plate having a thickness of 0.5 mm, and a plate thickness of 0, in order to confirm the vibration damping performance of the metal cover 1 of this embodiment. It is a graph which shows the result of having measured each loss factor (eta) of the laminated aluminum board of a single layer aluminum board of 0.5 mm, the metal cover 1, and plate | board thickness of 0.3 mm and 0.125 mm at room temperature. The loss factor for each material is shown in the table of FIG.

  From the table of FIG. 19 and FIG. 13, it was confirmed that the vibration damping performance of the metal cover 1 of the present embodiment is higher than any of the single-layer aluminum plated steel plate, single-layer aluminum plate, and laminated aluminum plate at room temperature. It was.

  FIG. 14 is a graph showing the results of measuring the temperature change of the loss coefficient η related to the vibration of various materials in relation to the metal cover 1 of the present embodiment. The measurement temperature range is between room temperature and about 250 ° C., the measurement result of the metal cover 1 is indicated by a curve g1, and the measurement result of an aluminum-plated steel plate having a thickness of 0.5 mm is indicated by a curve g2. The curve g3 is referred to in other embodiments described later.

  According to this measurement result, the loss factor of the metal cover 1 of the present embodiment is lower than the loss factor of the aluminum-plated steel sheet in the temperature range below about 100 ° C., but in the temperature range exceeding about 100 ° C. Further, it was confirmed that the loss factor was much higher than the loss factor of the aluminum-plated steel sheet and that the loss factor was almost constant in the range exceeding 100 ° C. Therefore, when the metal cover 1 is used for a vibration source that generates heat, such as an automobile engine, for example, it has been confirmed that it exhibits good vibration damping properties under the operation of the engine.

  In the present embodiment, the metal cover 1 is not only composed of a single thin plate material 4 but also a thin plate material 4 made of a damping alloy body, and a thin sheet of different thickness made of a damping alloy body. This includes the case of laminating plate materials, and further includes the case of laminating other types of metal sheets on the thin plate material 4 made of a damping alloy body. Further, this includes a case where synthetic resin sheets such as various rubbers and engineering plastics are laminated on the thin plate material 4 made of a damping alloy body.

(Second Embodiment)
FIG. 15 is a sectional view of the metal cover 1a according to the second embodiment of the present invention. FIG. 15 is a diagram corresponding to FIG. 6 of the first embodiment. The metal cover 1a of this embodiment is similar to the metal cover 1 of the first embodiment in terms of its structure and material, and corresponding parts are denoted by the same reference numerals.

  Hereinafter, with reference to FIG. 15, the metal cover 1a of 2nd Embodiment of this invention is demonstrated. A feature of this embodiment is that, instead of the metal cover 1 of the first embodiment shown in FIGS. 1 to 10, as an example, a laminate of a plurality of layers such as two layers is used. Details of the configuration are described below.

  As shown in FIG. 15, the metal cover 1 a of this embodiment is made of the same material as the thin plate material 4 in the above embodiment, and uses a thin plate material 5 having a plate thickness different from that of the thin plate material 4. One of the features is that the thin plate members 4 and 5 are laminated.

  The thin plate members 4 and 5 are selected so that the plate thicknesses are different from each other, for example, a plate thickness of 0.3 mm and a plate thickness of 0.125 mm. The resonance frequencies of the thin plate members 4 and 5 having different plate thicknesses are different from each other. Accordingly, by selecting different plate thicknesses, in the metal cover 1a of the present embodiment in which the thin plate members 4 and 5 are meshed with each other, the resonance frequencies of the thin plate members 4 and 5 cancel each other. Vibration and sound generated by the metal cover 1a itself can be remarkably suppressed.

  As described in the first embodiment with reference to FIGS. 4 to 10, the thin plate members 4 and 5 used in the cover 1 of the present embodiment have the raised portions 7 and the valley portions 8 alternately repeated. The plurality of corrugated shapes 9 extend along the first direction A1 and have a shape that continues along the second direction A2 that is a direction intersecting the first direction A1, preferably a direction perpendicular to the first direction A1. Yes. As shown in FIGS. 4 to 10, the raised portions 7 are alternately arranged with the first raised portions 10 and the second raised portions 11 rising from the valley portions 8 as shown in FIGS. 4 to 10. . Moreover, as the said trough part 8 is shown by FIGS. 4-10, the flat part 12 and the protrusion 13 are arranged alternately.

  Accordingly, as shown in FIG. 15, the protruding portion of the raised portion 7 of the thin plate material 5 fits into the inner peripheral portion of the raised portion 7 of the thin plate material 4 that is bent. Further, also in the second upright portion 11, the side walls 19, 20 are formed in a curved shape with a tip portion narrower than its base end portion. Even in such a second upright portion 11, the protruding portion of the second upright portion 11 of the thin plate material 5 is fitted into the curved inner peripheral portion of the second upright portion 11 of the thin plate material 4. Such portions such as the first upright portion 10, the second upright portion 11 and the trough portion 8 are meshing portions 40 in which the thin plate members 4 and 5 are slidably engaged with each other due to external vibration or bending displacement. It is configured as.

  With such a meshing portion 40, the thin plate members 4 and 5 can be firmly fixed to each other without using any special fixture or fastener. This is because the mutual coupling of the thin plate members 4 and 5 is due to the mechanical meshing relationship between them.

  Further, in the corrugated shape 9 along at least one of the first direction A1 and the second direction A2, the meshing portion 40 is folded on the thin plate members 4 and 5 by folding the thin plate members 4 and 5 themselves. The laminated portion 45 is configured.

  In the metal cover 1a of the present embodiment, as an example of the size of each part, as shown in FIG. 15, the length L1 of one cycle of the waveform shape 9 along the first direction A1, and the recess 23 of the second upright part 11 The length L2 is selected to be 11 mm and 5 mm, respectively. Of course, the technical scope of the present invention is not limited to such dimension examples, and the dimensions and the like are appropriately selected according to the required specifications of the metal cover 1a in which the invention is implemented. Is.

  As described above, the metal cover 1a of the present embodiment is different from the metal cover 1 of the first embodiment in that the single-layer structure of the thin plate material 4 is changed to the laminated structure of the thin plate materials 4 and 5. Since the structure is the same except for the above, it is obvious that in this embodiment, the same effects as the effects described in the first embodiment can be realized.

  Further, in the metal cover 1a of the present embodiment, as described above, the thin plate members 4 and 5 that are elastically deformable materials having the corrugated shape 9 formed on substantially the entire surface are configured to be slidable with respect to each other. The meshing portion 40 is configured, and the laminated portion 45 is further configured.

  In the present embodiment, the metal cover 1 a is laminated with the thin plate materials 4 and 5, and therefore vibrates due to the friction between the thin plate materials 4 and 5 due to mutual sliding of the plurality of thin plate materials 4 and 5 in the meshing portion 40. A substantial part of is converted into heat energy. Also by this, the vibration of the metal cover 1a itself due to the vibration received by the metal cover 1a can be further suppressed.

  In FIG. 14 referred to in the first embodiment, the loss factor η measured at room temperature of the metal cover 1a of the present embodiment is indicated by a measured value 0.0422 corresponding to the name of the laminated metal cover. Has been. When combined with the other measurement results described above, it was confirmed that the metal cover 1a has improved vibration damping performance in each stage as compared with the known sandwich steel plate, aluminum plate and laminated aluminum plate.

  In addition, the inventor measured the temperature change of the loss coefficient related to vibration for the metal cover 1a of the present embodiment. The measurement result is shown by the curve g3 in FIG. Comparing the curves g1 to g3 in FIG. 13, the metal cover 1a of the present embodiment is much more than the aluminized steel plate and the metal cover 1 of the first embodiment in the measured temperature range from room temperature to about 250 ° C. It was confirmed that it showed good vibration damping properties.

  As a result, the metal cover 1a that achieves a significantly higher vibration damping performance than the covers manufactured from the existing aluminized steel sheet can be significantly reduced in weight, so that the exhaust cover 3 of the metal cover 1a can be reduced. The number of attachment points can be reduced. Therefore, the number of bolts 31 for attachment and the number of attachment parts of the metal cover 1a can be reduced, and the configuration of the metal cover 1a can be simplified. Thereby, the manufacturing process can be simplified and the manufacturing cost can be reduced. Further, since the weight of the metal cover 1a can be reduced, it is possible to suppress damage due to fatigue at the site where the exhaust manifold 3 is attached due to vibration.

  Moreover, since the metal covers 1 and 1a are reduced in weight, the number of attachment parts and the number of attachment bolts to the exhaust manifold 3 can be reduced. Therefore, when recycling, the metal covers 1 and 1a are attached to the exhaust manifold 3. The work to remove from is greatly facilitated. In this respect, the man-hours for recycling can be significantly reduced.

(Third embodiment)
FIG. 16 is a cross-sectional view of the cover 1b according to the third embodiment of the present invention. This embodiment is similar to the first embodiment described above, and the same reference numerals are given to corresponding portions. The feature of the cover 1b is that the corrugated shape 9a formed on the thin plate material 4 is a rectangular shape. When the thin plate material 4 having the corrugated shape 9a having such a shape is press-molded into a three-dimensional shape, the corrugated shape 9a has a function of expanding and contracting. Therefore, it is obvious that even the cover 1b having such a corrugated shape can achieve the same effects as the various functions and effects described with respect to the cover 1 of the first embodiment. Further, in the present embodiment, the case where the waveform shape 9a having the rectangular shape is inclined in the left-right direction in FIG. 16 as shown by a two-dot chain line in FIG. 16 is also included as an embodiment of the present invention.

(Fourth embodiment)
FIG. 17 is a sectional view of a metal cover 1c according to the fourth embodiment of the present invention. This embodiment is similar to the first embodiment described above, and the same reference numerals are given to corresponding portions. The feature of the metal cover 1c is that the corrugated shape 9b formed on the thin plate material 4 has a triangular wave shape. When the thin plate member 4 having the corrugated shape 9b having such a shape is press-molded into a three-dimensional shape, the corrugated shape 9b has a function of expanding and contracting. Therefore, it is obvious that even the metal cover 1c having such a corrugated shape can realize the same effects as the various functions and effects described with respect to the metal cover 1 of the first embodiment. Further, in the present embodiment, the case where the waveform shape 9b having the triangular wave shape is inclined in the left-right direction of FIG. 17 as shown by a two-dot chain line in FIG. 17 is also included in the present embodiment.

(Fifth embodiment)
As the fifth embodiment of the present invention, the following configuration example can be implemented as the waveform shape 9 in each of the embodiments. In describing the waveform shape of the present embodiment, it will be described with reference to FIGS. 1 to 6 referred to in the first embodiment. In the second upright portion 11 of the raised portion 7 formed on the thin plate material 4, the corrugated shape of this embodiment is such that the side walls 14, 15 connected to the valley portion 8 are separated from the base end portion of the valley portion 8. That is, the shape is separated. That is, the side walls 14 and 15 of the present embodiment are characterized in that they are tapered while they are tapered in the case shown in FIG.

  When a thin plate material having such a corrugated shape is press-molded into a three-dimensional shape, the corrugated shape has a function of extending. Therefore, it is obvious that even the metal cover having such a corrugated shape can realize the same effects as the various functions and effects described with respect to the cover 1 of the first embodiment.

(Example of change)
The scope of the present invention is not limited to the above-described embodiments, and includes a wide variety of modifications without departing from the spirit of the present invention.

  In particular, in the metal covers 1 and 1a of the above-described embodiments, the corrugated shape 9 formed on the thin plate members 4 and 5 is not limited to the shape of the above-described embodiment, and is illustrated in FIG. 18 as an example. Such a case where the cross-sectional shape is a rectangular waveform shape 9a is possible, and a case where the cross-sectional shape is a triangular wave shape waveform shape 9b as shown in FIG. 19 is also possible.

  Even when the corrugated shapes of these shapes are formed, it is clear that the expanding and contracting operation of the corrugated shape accompanying the vibration can be realized, and the damping action by this expanding and contracting operation can be realized.

  The present invention is not limited to the cover for an automobile exhaust manifold described in the embodiment, but is widely implemented in industrial fields that require shielding of at least one of heat and vibration, such as an under cover of an automobile and a cover of an exhaust system. can do. Further, the present invention is not limited to automotive applications, and can be implemented in a wide range of industrial fields that suppress the dissipated heat and vibration with respect to a vibration source that generates heat and vibration.

1 is a front view of a state in which a metal cover 1 according to an embodiment of the present invention is mounted on an exhaust manifold 3. FIG. It is sectional drawing seen from the cut surface line X2-X2 of FIG. It is process drawing which shows the manufacturing process of the metal covers 1 of this embodiment. 1 is an enlarged front view of a metal cover 1. FIG. It is sectional drawing seen from the cut surface line X5-X5 of FIG. It is sectional drawing seen from the cut surface line X6-X6 of FIG. It is sectional drawing seen from the cut surface line X7-X7 of FIG. FIG. 2 is a simplified cross-sectional view viewed from a section line X8-X8 in FIG. It is sectional drawing seen from the cut surface line X9-X9 of FIG. It is a perspective view explaining the characteristic of this embodiment. 3 is a cross-sectional view for explaining the expansion and contraction action of the metal cover 1. FIG. 4 is a graph for explaining a vibration damping action of the metal cover 1. 4 is a graph showing a loss factor of the metal cover 1. 4 is a graph showing a temperature change of a loss coefficient of the metal cover 1. It is sectional drawing corresponding to FIG. 6 of the metal covers 1a of 2nd Embodiment of this invention. It is sectional drawing corresponding to FIG. 6 of the metal cover 1b of 3rd Embodiment of this invention. It is sectional drawing corresponding to FIG. 6 of the metal cover 1c of 4th Embodiment of this invention. It is a perspective view of background art. It is a figure which shows a table | surface.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1, 1a, 1b, 1c Metal cover 3 Exhaust manifold 4, 5 Thin plate material 7 Raised part 8 Valley part 9, 9a, 9b Corrugated shape 10 1st standing part 11 2nd standing part 13 Concave part 28 Flange 30 Main ridge line equivalent site 31 bolt 40 meshing portion 45 stacking portion A1 first direction A2 second direction

Claims (3)

In order to suppress at least one of vibration and heat from a target member that generates at least one of vibration and heat, a method for manufacturing a vibration damping panel disposed at an interval facing the target member,
The damping panel comprises Al and Fe, and a predetermined Al material and Fe material are melted under reduced pressure so that the Al content is 6 to 10% by weight. A first step of casting
A second step of processing the damping alloy body ingot to form a damping alloy body thin plate;
A third step of forming the corrugated panel by processing the damping alloy sheet into a corrugated shape;
A fourth step of manufacturing a vibration control panel by pressing the corrugated panel to form a product shape,
In any one of the second to fourth steps, the intermediate material made of the damping alloy body is heated to a heating temperature selected from a plurality of predetermined heating temperatures, and thereafter, from a plurality of predetermined temperature change modes A method of manufacturing a vibration damping panel, comprising a heat treatment step of gradually cooling in a selected temperature change mode. In the damping alloy sheet, a wave shape in which valleys and ridges are alternately repeated is formed continuously along the first direction, and along the second direction intersecting the first direction, the valleys and The method for manufacturing a vibration damping panel according to claim 1, wherein waveform shapes in which the raised portions are alternately repeated are formed continuously. 3. The method for manufacturing a vibration damping panel according to claim 1, wherein in the heat treatment step, a heating temperature of about 850 ° C. is included as a plurality of predetermined heating temperatures. 4.

Images