JP2023145245A - Manufacturing method of joint structure - Google Patents

Abstract

To provide a manufacturing method of a joint structure in which a plurality of plates are joined without welding and without using a separate member from the plurality of plates.SOLUTION: A manufacturing method of a joint structure comprises steps of: preparing a plurality of metal plates including a first plate and a second plate; overlapping the plurality of plates to form a laminated region where each of the first plate and the second plate becomes an outermost layer; radially making a cut penetrating the first plate at the laminated region to form a plurality of first pieces partitioned from each other; bending the plurality of first pieces in a first direction from the first plate to the second plate to form a first through hole in the first plate coaxially with a second through hole in the second plate; and folding back the plurality of first pieces into an outer peripheral side of the first through hole to sandwich the second plate between the first piece and the first plate.SELECTED DRAWING: Figure 2

Description

The present invention relates to a method for manufacturing a joined structure in which a plurality of plate materials are joined.

Patent Document 1 discloses spot welding. In spot welding, a plurality of panels are sandwiched between a pair of electrodes facing each other, and the plurality of panels are welded by applying electricity between the pair of electrodes.

Japanese Patent Application Publication No. 2004-306096

In spot welding, for example, when welding plates of different metals together, intermetallic compounds are formed in the welded portion. However, when intermetallic compounds are formed, the weld becomes brittle and the joint strength decreases. As a means of joining a plurality of plate materials without welding, for example, caulking using rivets can be mentioned. However, a separate member is required in addition to the plurality of plate materials, which increases the number of parts.

One of the objects of the present invention is to provide a method for manufacturing a joined structure in which a plurality of plate materials are joined without welding and without using a separate member from the plurality of plate materials.

A method for manufacturing a bonded structure according to one embodiment of the present invention includes:
a step of preparing a plurality of plate materials including a first plate material and a second plate material made of metal;
a step of stacking the plurality of plate materials on top of each other to provide a laminated region having each of the first plate material and the second plate material as the outermost layer;
forming a plurality of first pieces separated from each other by making radial cuts that penetrate the first plate material in the laminated region;
A first through hole coaxial with a second through hole of the second plate is formed in the first plate by bending the plurality of first pieces in a first direction from the first plate to the second plate. process and
sandwiching the second plate material between the first piece and the first plate material by folding the plurality of first pieces to the outer circumferential side of the first through hole,
The second through hole satisfies the following requirement (A) or requirement (B).
(A) In the step of forming the plurality of first pieces, a plurality of second pieces separated from each other are formed by making radial cuts that pass through the second plate material together with the first plate material, and The through hole is formed by bending the plurality of second pieces together with the plurality of first pieces in the first direction in the step of forming the through hole.
(B) It is provided in advance on the second plate material in the preparing step.

The above method for manufacturing a bonded structure can manufacture a bonded structure in which a plurality of plate materials are bonded by a plurality of first pieces formed of a part of the first plate material and the first plate material by performing each of the above steps. . That is, the above method for manufacturing a joined structure can join a plurality of plate materials without welding them to each other. Therefore, in the method for manufacturing a bonded structure described above, even if the plurality of plate materials are made of different metals, the plurality of plate materials can be joined without forming a weak point such as an intermetallic compound. Furthermore, the method for manufacturing a bonded structure described above allows a plurality of plate materials to be bonded without using a separate member from the plurality of plate materials. Therefore, in the above method for manufacturing a bonded structure, the number of parts does not increase, so that an increase in cost can be suppressed.

FIG. 1 is an explanatory diagram illustrating steps A to D of a method for manufacturing a bonded structure according to an embodiment. FIG. 2 is an explanatory diagram illustrating step E of the method for manufacturing a bonded structure according to the embodiment. FIG. 3 is a cross-sectional view showing a joined structure manufactured by the method for manufacturing a joined structure according to the embodiment. FIG. 4 is an explanatory diagram illustrating a plurality of first pieces formed in step C in the method for manufacturing a bonded structure according to the embodiment. FIG. 5 is an explanatory diagram illustrating a method for manufacturing a bonded structure according to a modification.

《Embodiment》
[Method for manufacturing bonded structure]
A method for manufacturing a bonded structure according to an embodiment will be described below with reference to FIGS. 1 to 4. In FIGS. 1 and 2, for convenience of explanation, hatching of the cross sections of the plurality of plate members 10 is omitted. In the method for manufacturing a bonded structure according to the embodiment, a plurality of plate materials 10 are bonded to each other. The method for manufacturing a bonded structure according to the embodiment includes a step A of preparing a plurality of plate materials 10, and a step B of providing a laminated region in which the plurality of plate materials 10 are stacked on top of each other. One of the features of the method for manufacturing a bonded structure according to the embodiment is that it further includes specific steps C to E. In the following description, the first plate material 11 side of the second plate material 12 will be referred to as the top, and the second plate material 12 side of the first plate material 11 will be referred to as the bottom.

[Process A]
All of the plurality of plates 10 prepared in step A may have the same constituent material, or the constituent material of at least one plate may be different from the constituent material of the remaining plates. The same constituent materials mean that the types of constituent elements are the same and the contents of the constituent elements are the same. The term "constituent materials are different" means that the types of constituent elements are different, or that the types of constituent elements are the same and the contents of the constituent elements are different.

In this embodiment, the plurality of plates 10 are two plates, a first plate 11 and a second plate 12. The constituent material of the first plate material 11 is metal. Examples of metals are aluminum, aluminum alloys, iron, and iron alloys. The first plate material 11 of this embodiment is an iron plate. The constituent material of the second plate material 12 is metal in this embodiment. An example of the metal is the same as the first plate material 11. The second plate material 12 of this embodiment is an aluminum plate. Unlike this embodiment, the constituent material of the second plate member 12 may be a non-metallic material. An example of a non-metallic material is resin or rubber. Unlike this embodiment, the plurality of plate members 10 may be three or more plate members.

[Process B]
In step B, as shown in the left diagram of FIG. 1, a plurality of plate materials 10 are stacked so that each of the first plate material 11 and the second plate material 12 is located at the outermost layer of the lamination area. A first plate material 11 and a first tool 1, which will be described later, face each other, and a second plate material 12 and a second tool 2, which will be described later, face each other. Here, the first plate material 11 is stacked on the second plate material 12. Unlike this embodiment, when the number of the plurality of plates 10 is three or more, plates other than the first plate 11 and the second plate 12 are arranged between the first plate 11 and the second plate 12.

[Process C]
In step C, as shown in the center view of FIG. 1, radial cuts are made in the first plate material 11 in the laminated region to penetrate the first plate material 11. An example of the notch 11a formed in the first plate material 11 is shown in FIG. FIG. 4 shows the notch 11a formed in the first plate material 11 as seen in the direction from the first tool 1 to the second tool 2. As shown in FIG. By forming the cuts 11a, a plurality of first pieces 11b are formed in the first plate material 11. The number of first pieces 11b is not particularly limited as long as it is three or more. In this embodiment, four first pieces 11b are formed. The plurality of first pieces 11b are separated from each other by notches 11a.

In this embodiment, radial cuts are made in the second plate material 12 as well as the first plate material 11 to pass through the second plate material 12. Although not shown, the cuts formed in the second plate material 12 are similar to the cuts in the first plate material 11. For example, if a cut 11a shown in FIG. 4 is formed in the first plate material 11, a cut similar to the cut 11a shown in FIG. 4 is also formed in the second plate material 12. A plurality of second pieces 12b are formed in the second plate material 12 by the cuts in the second plate material 12. The plurality of second plate pieces are separated from each other.

Unlike this embodiment, when the plurality of plates 10 are three or more, radial cuts are made that pass through each of the plates other than the first plate 11 as well as the first plate 11 to separate them from each other. Form multiple pieces. The cuts formed in the plate materials other than the first plate material 11 are similar to the cuts in the first plate material 11. The second plate material 12 is included in the plate materials other than the first plate material 11 .

Steps C to E, which will be described later, can be performed using, for example, the first tool 1 and the second tool 2. The first tool 1 and the second tool 2 are provided at the tip of one robot arm (not shown). The first tool 1 and the second tool 2 are moved to desired positions by a robot arm. The first tool 1 and the second tool 2 are facing each other. The first tool 1 and the second tool 2 are moved forward and backward by a drive mechanism (not shown). Moving forward means that the first tool 1 and the second tool 2 move in a direction toward each other. Retreating means that the first tool 1 and the second tool 2 move in a direction away from each other.

Process C can be performed using the first tool 1. The shape of the first tool 1 is not particularly limited as long as it is a tool that can form a notch without cutting the first plate material 11 as much as possible. The first tool 1 of this embodiment has a base portion 1a and a tip portion 1b. The shape of the base portion 1a is cylindrical or prismatic. The base portion 1a and the tip portion 1b are formed in series. The tip portion 1b has three or more cutting edges. Three or more cutting edges are provided radially from the center of the tip portion 1b toward the outer periphery. Since the number of cutting edges is three or more and they are provided radially, three or more formed first pieces 11b can be bent in step D described later. When the base portion 1a has a prismatic shape, the cutting edges are preferably provided so as to extend radially in diagonal directions. In this case, the first piece 11b and the second piece 12b are easily bent at the base portion 1a. The greater the number of cutting edges, the easier it is to bend each first piece 11b. An example of the number of cutting edges is three, four, five, or six. Of course, the number of cutting edges may be seven or more. Each of the three or more cutting edges extends linearly from the center of the tip of the first tool 1 toward the outer periphery. The cut 11a shown in FIG. 4 is an example in which the cut 11a is formed in the first plate material 11 using the first tool 1 provided at the tip 1b so that four cutting edges extend radially from the center of the tip toward the outer circumference. be. The tip portion 1b may be tapered. If the tip is tapered, not only it is easy to form a cut, but also it is easy to bend the plurality of first pieces 11b in step D, which will be described later.

From the initial position of the first tool 1 shown in the left diagram of FIG. 1, the first tool 1 is advanced as shown in the center diagram of FIG. The cutting edge of the tip portion 1b of the first tool 1 that has moved forward comes into contact with the first plate material 11. The first tool 1 is advanced to a position where it penetrates the first plate material 11 over the entire length of the cutting edge. When the first plate material 11 is advanced to that position, radial cuts 11a penetrating the first plate material 11 as shown in FIG. 4 are formed in the first plate material 11, for example. The first tool 1 is advanced to a position where the second plate material 12 is penetrated over the entire length of the cutting edge. When the first tool 1 advances to that position, a notch is formed in the second plate material 12, although not shown, passing through the second plate material 12. This cut is similar to the cut 11a shown in FIG. 4, for example. The first tool 1 may be vibrated to facilitate formation of the notch.

When forming the cuts in the first plate material 11, it is preferable to use the first support mechanism 4. The first support mechanism 4 supports the plurality of plate materials 10 from the side opposite to the first tool 1 of the plurality of plate parts. The first support mechanism 4 of this embodiment has a first leg portion 4a and a first drive mechanism 4b. The first leg portion 4a supports the lower surface of the second plate member 12. The first leg portion 4a is arranged to surround the outer periphery of the second tool 2. A gap is provided between the first leg portion 4a and the second tool 2. The first leg portion 4a has a cylindrical shape or a rectangular tube shape. FIG. 1 shows a cross section of the first leg portion 4a. In FIG. 1, for convenience of explanation, the hatching of the cross section of the first leg portion 4a is omitted. The end surface of the first leg portion 4a is configured as a flat surface. The end face of the first leg portion 4a has a circular frame shape or a square frame shape. The first drive mechanism 4b raises and lowers the first leg portion 4a. The type of first drive mechanism 4b is not particularly limited. The first drive mechanism 4b may be a spring cylinder or an air cylinder. The first leg portion 4a is moved to a position where the end surface of the first leg portion 4a contacts the lower surface of the second plate member 12 by the first drive mechanism 4b. Support by the first leg portion 4a makes it easy for the first tool 1 to cut into the first plate material 11 in step C, and makes it easier for the first tool 1 to bend the first piece 11b in step D, which will be described later.

[Process D]
In step D, as shown in the right diagram of FIG. 1, the plurality of first pieces 11b are bent in a first direction from the first plate material 11 toward the second plate material 12. A first through hole 11c is formed in the first plate material 11 by bending the plurality of first pieces 11b.

In this embodiment, the plurality of second pieces 12b are bent in the first direction together with the plurality of first pieces 11b. A second through hole 12c is formed in the second plate material 12 by bending the plurality of second pieces 12b. The first through hole 11c and the second through hole 12c of the second plate material 12 are coaxial.

Unlike this embodiment, when the number of the plurality of plate materials 10 is three or more, each of the plurality of pieces of the plate materials other than the first plate material 11 is bent in the first direction together with the plurality of first pieces 11b. Through-holes are formed in each of the plate materials other than the first plate material 11 by bending a plurality of pieces of each of the plate materials other than the first plate material 11. Each through hole and the first through hole 11c are coaxial.

Step D can be performed using the first tool 1 described above. Continuing with the formation of the cuts in the first plate material 11 by the first tool 1 advanced in step C, the plurality of first pieces 11b can be bent as shown in the right figure of FIG. The plurality of first pieces 11b are bent using the base portion 1a of the first tool 1. Further, the plurality of second pieces 12b can be bent successively after forming the notches in the second plate material 12. The plurality of second pieces 12b are bent by bending the plurality of first pieces 11b. The second tool 2 is moved back to a position where it does not come into contact with the advanced first tool 1. Since the tip portion 1b of the first tool 1 is tapered, the plurality of first pieces 11b are easily bent toward the first direction as the first tool 1 is advanced. As the first piece 11b is bent, the plurality of second pieces 12b are also bent toward the first direction.

By advancing the first tool 1, a plurality of first pieces 11b and a plurality of second pieces 12b along the first direction can be formed, as shown in the right figure of FIG. A first through hole 11c is formed by the inner peripheral edges of the plurality of first pieces 11b along the first direction. The inner dimension of the first through hole 11c is substantially the same as the outer dimension of the base portion 1a of the first tool 1. A second through hole 12c is formed by the inner peripheral edges of the plurality of second pieces 12b along the first direction. The inner dimension of the second through hole 12c is substantially the same as the outer dimension of the plurality of first pieces 11b. The inner dimension of the lower end of each through hole increases in stages by the thickness of each of the plurality of plate materials 10.

[Process E]
In step E, the plurality of first pieces 11b are folded back to the outer peripheral side of the first through hole 11c. The second plate material 12 is sandwiched between each first piece 11b and the first plate material 11 by plastically deforming the plurality of first pieces 11b so as to fold back.

In this embodiment, the plurality of second pieces 12b are folded back toward the outer circumferential side together with the plurality of first pieces 11b. By folding back the plurality of second pieces 12b, the plurality of second pieces 12b and the second plate material 12 are sandwiched between each of the plurality of first pieces 11b and the first plate material 11.

Unlike this embodiment, when the number of the plurality of plate materials 10 is three or more, pieces of the plurality of plate materials 10 are folded back toward the outer circumferential side. By folding back the pieces of the plurality of plate materials 10, the pieces of plate materials other than the first plate materials 11 and the plate materials other than the first plate materials 11 are sandwiched between the plurality of first pieces 11b and the first plate materials 11.

Step E can be performed by advancing the second tool 2. The shape of the tip end surface 2a of the second tool 2 is not particularly limited as long as it is a shape that allows each first piece 11b to be folded back toward the outer circumferential side. For example, if the tip surface 2a of the second tool 2 is inclined downward from the center toward the outer periphery, each first piece 11b can be easily folded back toward the outer periphery.

The second tool 2 is advanced as shown in the left, center, and right views of FIG. The forward end surface 2a of the second tool 2 comes into contact with the plurality of first pieces 11b. The second tool 2 is advanced so that the plurality of second pieces 12b are in contact with the lower surface of the second plate material 12. By this forward movement, as shown in FIG. 3, a joined structure in which the plurality of second pieces 12b and the second plate material 12 are sandwiched between the plurality of first pieces 11b and the first plate material 11 is manufactured. . Therefore, the method for manufacturing a joined structure of this embodiment can join the plurality of plate materials 10 without welding and without using a member separate from the plurality of plate materials 10. The method for manufacturing a bonded structure according to this embodiment does not increase the number of parts, so it is possible to suppress an increase in cost. Moreover, since the above-mentioned joined structure can be manufactured by replacing the tips of the existing robot arm with the first tool 1 and the second tool 2, capital investment can be suppressed. In particular, a robot arm having a welding gun can be suitably used as an existing robot arm. The welding gun includes a pair of welding electrodes that face each other and are moved toward or away from each other. By providing the first tool 1 and the second tool 2 instead of this pair of welding electrodes, the method for manufacturing a joined structure of this embodiment can be executed. In other words, equipment costs can be saved by using existing equipment.

When folding back the plurality of first pieces 11b, it is preferable to use the second support mechanism 5 shown in FIGS. 1 and 2. The second support mechanism 5 supports the plurality of plate materials 10 from the side opposite to the second tool 2 of the plurality of plate materials 10. The second support portion of this embodiment has a second leg portion 5a and a second drive mechanism 5b similar to the first leg portion 4a and first drive mechanism 4b of the first support mechanism 4. The second leg portion 5a is moved to a position where the end surface of the second leg portion 5a contacts the upper surface of the first plate member 11 by the second drive mechanism 5b. The support by the second leg portions 5a makes it easy for the second tool 2 to fold back the plurality of first pieces 11b toward the outer circumferential side in step E.

When forming a plurality of joints, steps C to E are repeated.

《Modification 1》
In modification 1, as shown in FIG. 5, the first tool 1 may perform the process C and the process D, and the third tool 3 may perform the process E. The first tool 1 and the third tool 3 are provided at the tips of mutually different robot arms. The first tool 1 is as described in the embodiment. The second tool 2 described above with reference to FIG. 2 is not provided at the tip of the robot arm where the first tool 1 is provided. The third tool 3 includes a first member 3a and a second member 3b that sandwich the plurality of plate materials 10 from both sides in the stacking direction. The distal end surface of the first member 3a is configured as a flat surface. The distal end surface of the second member 3b is similar to the distal end surface 2a of the second tool 2 described above with reference to FIG. The distal end surface of the first member 3a and the distal end surface of the second member 3b are surfaces facing each other. In step E, the first member 3a is advanced so that the distal end surface of the first member 3a contacts the upper surface of the first plate material 11, and then the second member 3b is advanced. In the process C and the process D of this example, it is preferable to use the first support mechanism 4 similarly to the embodiment. The first support mechanism 4 may be provided on a robot arm, or may be provided on a jig for fixing a plurality of plate materials 10 in a stacked state. Furthermore, in steps C and D, a fixed pedestal may be used instead of the first support mechanism 4. In this example, the second support mechanism 5 shown in FIGS. 1 and 2 can be made unnecessary.

《Modification 2》
In Modification 1, at least one plate material other than the first plate material among the plurality of plate materials prepared in step A may be provided with a through hole in advance. For example, the plurality of plate members may be two plate members, a first plate member and a second plate member, and the second plate member may be provided with a second through hole in advance. In this case, in step B, a lamination region is provided in which the first plate material is stacked on the second plate material so that the second through hole is covered with the first plate material. In step C, radial cuts are made through the first plate material at locations overlapping the second through holes in the first plate material. Steps D and E are as described in the embodiment. In this example, the peripheral edge of the second through hole of the second plate is sandwiched between the first piece and the first plate.

The present invention is not limited to these examples, but is indicated by the scope of the claims, and is intended to include all changes within the meaning and scope equivalent to the scope of the claims.

10 Plurality of plate materials 11 First plate material, 11a Notch, 11b First piece, 11c First through hole 12 Second plate material, 12b Second piece, 12c Second through hole 1 First tool, 1a Base, 1b Tip portion 2 2 tool, 2a tip surface 3 third tool, 3a first member, 3b second member 4 first support mechanism, 4a first leg, 4b first drive mechanism 5 second support mechanism, 5a second leg, 5b Second drive mechanism

Claims (1)

a step of preparing a plurality of plate materials including a first plate material and a second plate material made of metal;
a step of stacking the plurality of plate materials on top of each other to provide a laminated region having each of the first plate material and the second plate material as the outermost layer;
forming a plurality of first pieces separated from each other by making radial cuts that penetrate the first plate material in the laminated region;
A first through hole coaxial with a second through hole of the second plate is formed in the first plate by bending the plurality of first pieces in a first direction from the first plate to the second plate. process and
sandwiching the second plate material between the first piece and the first plate material by folding the plurality of first pieces to the outer circumferential side of the first through hole,
The second through hole satisfies the following requirements (A) or (B):
A method for manufacturing a bonded structure.
(A) In the step of forming the plurality of first pieces, a plurality of second pieces separated from each other are formed by making radial cuts that pass through the second plate material together with the first plate material, and The through hole is formed by bending the plurality of second pieces together with the plurality of first pieces in the first direction in the step of forming the through hole.
(B) It is provided in advance on the second plate material in the preparing step.

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