JP4230062B2

JP4230062B2 - Method for manufacturing a member in which irregularities are formed in a joint

Info

Publication number: JP4230062B2
Application number: JP21051199A
Authority: JP
Inventors: 光男服部
Original assignee: Showa Denko KK
Current assignee: Showa Denko KK
Priority date: 1999-07-26
Filing date: 1999-07-26
Publication date: 2009-02-25
Anticipated expiration: 2019-07-26
Also published as: JP2001038476A

Description

【０００１】
【発明の属する技術分野】
この発明は、例えば足場材や装飾材に用いる、アルミニウムまたはアルミニウム合金（以下、アルミニウムという）等からなる、接合部に凹凸が形成された部材の製造方法に関する。
【０００２】
【従来の技術及び発明が解決しようとする課題】
近年、例えば足場材や装飾材として、軽量かつ高強度であることに加えて量産に適するという利点から、アルミニウムからなるものが汎用されている。そして、このような足場材や装飾材の製造方法の一つとして、分割された構成部材を突き合わせるとともに、この状態で該突き合せ部において、入熱量が少なく熱歪み等が生じにくい固相接合法の一つである摩擦撹拌接合を実施する方法が提案されている。
【０００３】
ところで、上記の足場材において、作業者が足を滑らす危険を防止するために、足場材の表面に滑り止め用の凹凸を設ける場合がある。また、上記の装飾材においては、装飾効果を向上させるために、装飾材の表面に装飾用の凹凸を設ける場合がある。しかるに、従来においては、前記構成部材を摩擦撹拌接合により接合一体化して足場材あるいは装飾材を製作したあと、さらに足場材あるいは装飾材の表面に切削加工等の公知の加工を施して、滑り止め用凹凸あるいは装飾用凹凸を形成するものであったため、加工に非常に手間がかかって足場材あるいは装飾材の生産性が低下するという問題があった。
【０００４】
この発明は上述の問題に鑑みてなされてものであって、接合部に凹凸を簡単かつ確実に形成することができる、接合部に凹凸が形成された部材の製造方法を提供することを目的とする。
【０００５】
【課題を解決するための手段】
上記目的を達成するために、この発明に係る接合部に凹凸が形成された部材の製造方法は、周面に凹凸が連続して形成された歯車状の支持ローラに、プローブを近接配置し、突合せ状態に配置した構成部材を前記支持ローラとプローブとの間に介在させて、前記構成部材を前記支持ローラにより厚さ方向に支持するとともに、突合せ部に回転する前記プローブが挿入された状態となし、この状態で突合せ部が順次プローブを通過するように前記構成部材を移動させるとともに、自軸回転する前記支持ローラ周面の凹凸により、前記構成部材におけるプローブとの接触部を構成部材の厚さ方向に振動させることによって、突き合せ部をプローブとの摩擦熱にて順次軟化させ撹拌して前記構成部材を接合一体化すると同時に、前記構成部材の接合部に波形の凹凸を連続して形成することを特徴とする。
【０００６】
これによれば、構成部材の突き合せ部において摩擦撹拌接合を実施する際、構成部材におけるプローブとの接触部は、支持ローラの周面に形成された凹凸によって、構成部材の厚さ方向に振動するため、構成部材の突き合せ部が摩擦撹拌接合により接合一体化すると同時に、構成部材の接合部に波形の凹凸が形成され、表面に凹凸が形成された部材を簡単かつ確実に製造することができる。
【０００７】
また、この発明の他のものは、支持ローラに、プローブを近接配置し、突合せ状態に配置した構成部材と一面に凹凸部を有するラックとを、構成部材がプローブ側に、ラック状部材の前記凹凸部が支持ローラ側に位置するように重ね合わせて、前記支持ローラとプローブとの間に介在させ、前記構成部材を前記支持ローラにより厚さ方向に支持するとともに、突合せ部に回転する前記プローブが挿入された状態となし、この状態で突合せ部が順次プローブを通過するように前記ラックと構成部材を一体的に移動させるとともに、自軸回転する前記支持ローラの周面をラックの凹凸部が通過することにより、前記構成部材におけるプローブとの接触部を構成部材の厚さ方向に振動させることによって、突き合せ部をプローブとの摩擦熱にて順次軟化させ撹拌して前記構成部材を接合一体化すると同時に、前記構成部材の接合部に波形の凹凸を連続して形成することを特徴とする、接合部に凹凸が形成された部材の製造方法にある。
【０００８】
この製造方法によっても、自軸回転する前記支持ローラの周面をラックの凹凸部が通過することにより、前記構成部材におけるプローブとの接触部が構成部材の厚さ方向に振動するから、構成部材の突き合せ部が摩擦撹拌接合により接合一体化すると同時に、構成部材の接合部に波形の凹凸が形成され、表面に凹凸が形成された部材を簡単かつ確実に製造することができる。
【０００９】
【発明の実施の形態】
以下、この発明に係る接合部に凹凸が形成された部材の製造方法を、図１〜図３に示す一実施形態を参照して説明する。この実施形態は、２個の長尺な板状の構成部材（１）（１）の突き合わせ接合を行うことによって、足場材（Ａ）を製造しようとするものである。
【００１０】
前記構成部材（１）は、図１に示すように、帯状平板部（１ａ）と、その表面の幅方向一端部において長さ方向に沿って垂設されたリブ（１ｂ）とを有するアルミニウム押出型材からなり、リブ（１ｂ）が形成された幅方向一端部の端面同士が突き合わされた状態となされている。
【００１１】
前記リブ（１ｂ）は、後述するように摩擦撹拌接合を実施する部位であると同時に、その上面に波形の滑り止め用凹凸（６）を形成する部位である。リブ（１ｂ）の高さは、構成部材（１）（１）に対して滑り止め用凹凸（６）が適度に形成されるように、望ましくは構成部材（１）の板厚の１／１０〜１／２程度となされるのがよい。
【００１２】
また、前記構成部材（１）には、突合せ状態の構成部材（１）（１）と同大・同形の金属製のラック（２）が、その周縁部を前記構成部材（１）（１）の周縁部に一致させ、かつその上面を前記構成部材（１）（１）の下面に接する態様で配置されている。このラック（２）は、後述するように構成部材（１）（１）を接合一体化するに際し、接合工具（１０）のプローブ（１２）が構成部材（１）（１）を貫通し、後述の支持ロール（３）と接触するのを防止するためのものである。
【００１３】
（３）は構成部材（１）（１）及びラック（２）を下方から支持するとともに、構成部材（１）（１）のリブ（１ｂ）（１ｂ）の上面に波形の滑り止め用凹凸（６）を形成するための支持ローラである。この支持ローラ（３）の周面には、支持ローラ（３）の長さ方向に沿った複数の凸条（３ａ）が、周方向に一定ピッチで連続して設けられており、これにより支持ローラ（３）は周面が凹凸に形成された歯車状となされている。そして、ローラ長さは突き合わせ状態の構成部材（１）（１）の幅寸法和より若干長く設定され、構成部材（１）（１）及びラック（２）の移動に従って自軸回転するものとなされている。しかして、前記ラック（２）の裏面を前記支持ローラ（３）の凸条（３ａ）に当接支持させた状態で、前記構成部材（１）（１）及びラック（２）を一体に移動させると、両構成部材（１）（１）における後述のプローブ（１２）との接触部は、自軸回転する支持ローラ（３）の周面に形成された凹凸によって、構成部材（１）（１）の厚さ方向に振動する。このため、構成部材（１）（１）のリブ（１ｂ）（１ｂ）は、後述するように摩擦撹拌接合による接合一体化と同時に、その上面に支持ローラ（３）の凹凸ピッチに対応したピッチを有する、波形の滑り止め用凹凸（６）が連続して形成される。なお、支持ローラの凹凸ピッチが異なれば、構成部材（１）（１）のプローブ（１２）との接触部の振動周期も異なって、接合部に形成される滑り止め用凹凸のピッチも異なるので、滑り止め用凹凸（６）のピッチを変更したい場合は、それに合わせて所定の凹凸ピッチを有する支持ローラに取り替えればよい。
【００１４】
前記支持ローラ（３）の上方における両構成部材（１）（１）の突き合せ部が通過する位置には、径大の円柱回転子（１１）と、該回転子（１１）の端部軸線上に一体に設けられた径小のピン状のプローブ（１２）とを有する接合工具（１０）が、前記プローブ（１２）を前記支持ローラ（３）の周面に近接させる態様にして配置されている。前記接合工具（１０）は、前記回転子（１１）を回転させることによりプローブ（１２）も回転させ得るものとなされており、また前記プローブ（１２）及び回転子（１１）は、構成部材（１）（１）よりも硬質でかつ接合時に発生する摩擦熱に耐え得る耐熱材料によって形成されている。なお、（１１ａ）は回転子（１１）のプローブ（１２）側平坦面からなる肩部である。このように支持ローラ（３）とプローブ（１２）とを配置することよって、両構成部材（１）（１）及びラック（２）は、支持ローラ（３）とプローブ（１２）間に介在され、前記支持ローラ（３）に支持されるとともに、両構成部材（１）（１）の突き合せ部に前記プローブ（１２）が挿入される態様となされる。
【００１５】
また、両構成部材（１）（１）及びラック（２）の移動方向における前記支持ローラ（３）の前後には、前記支持ローラ（３）の歯元円と同径の円柱状の駆動ローラ（４）が、前記支持ローラ（３）の軸位置と同じ高さの軸位置で前記支持ローラ（３）と並行に配置されている。これら前後の駆動ローラ（４）（４）は、前記支持ローラ（３）とともに両構成部材（１）（１）及びラック（２）を支持するほか、前記図示略の駆動機構により回転駆動されることによって、構造部材（１）（１）及びラック（２）をその長さ方向の一方側に移動させるものである。そして、この駆動ローラ（４）（４）は、上述のように支持ローラ（３）の歯元円と同径、すなわち支持ローラ（３）よりも凸条（３ａ）の高さの分だけ小さい径となされているため、構成部材（１）（１）のプローブ（１２）との接触部は、支持ローラ（３）の凸条（３ａ）の高さ分までプローブ（１２）側にたわむ方向に押し出され得ることになり、支持ローラ（３）周面の凹凸による振動が起こりやすくなっている。
【００１６】
また、両構成部材（１）（１）の移動方向における前記プローブ（１２）の前後には、互いに同形・同寸の回転自在な押えローラ（５）が、前記駆動ローラ（４）と両構成部材（１）（１）の厚さ方向に対向する態様にして配置されている。この押えローラ（５）は、図示略の加圧機構を備えており、両構成部材（１）（１）及びラック（２）の移動に伴って、その周面を両構成部材（１）（１）の上面に圧接させながら自由に自軸回転するものとなされている。このため、支持ローラ（３）とプローブ（１２）との間に介在された構成部材（１）（１）及びラック（２）は、これら押えローラ（５）によって前記駆動ローラ（４）に押し付けられて、スリップを生じることなく一体に移動方向の駆動力が付与される。なお、駆動ローラ（４）によることなく、構成部材（１）（１）の長さ方向後端部を押圧して、構成部材（１）（１）を移動させるものとしてもよい。
【００１７】
次に、上記摩擦撹拌接合装置を用いて足場材を製造する方法について説明する。
【００１８】
まず、プローブ（１２）を支持ローラ（３）の上方離間位置に待機させた状態で、突き合わせ状態の構成部材（１）（１）と、該構成部材（１）（１）の下面に周縁部を一致させて配置したラック（２）とを、その長さ方向の一端部から押えローラ（５）と回転駆動している駆動ローラ（４）との間に通す。
【００１９】
押えローラ（５）と駆動ローラ（４）との間に通された両構成部材（１）（１）及びラック（２）は、押えローラ（５）により駆動ローラ（４）の周面に押し付けられてることによって、回転駆動している駆動ローラ（４）から駆動力が付与されて、この駆動力によりプローブ（１２）と支持ローラ（３）との間に向かって一体に移動する。
【００２０】
両構成部材（１）（１）の突き合せ部の接合開始予定位置が、プローブ（１２）の下方位置に到達したとき、駆動ローラ（４）の駆動を停止することにより構成部材（１）（１）及びラック（２）の一旦停止する。そして、プローブ（１２）を回転させながら下降させ、プローブ（１２）の先端を構成部材（１）（１）の突き合せ部に接触させると、該接触部は摩擦熱により軟化するため、さらにプローブ（１２）を下降させて突き合せ部に挿入し、先端部がラック（２）に接触する直前で停止固定する。なお、両構成部材（１）（１）の下面にラック（２）が配置されているので、万一、プローブ（１２）が両構成部材（１）（１）の突き合せ部を貫通しても、前記支持ローラ（３）に接触して支持ローラ（３）を破損させることを防止できる。
【００２１】
こうして、構成部材（１）（１）及びラック（２）を、支持ローラ（３）とプローブ（１２）との間に介在させて、プローブ（１２）が突き合せ部に挿入されるとともに、ラック（２）の下面が支持ローラ（３）の凹凸面に当接支持された状態となす。なお、プローブ（１２）をあらかじめ下降させておき、プローブ（１２）と支持ローラ（３）との間に構成部材（１）（１）を強制的に通すことによって、プローブ（１２）が側方から突き合わせ部に潜り込んで挿入状態となるようにしてもよい。
【００２２】
次に、駆動ローラ（４）を再駆動すると、構成部材（１）（１）及びラック（２）は駆動力が付与されて、構成部材（１）（１）の突き合せ部にプローブ（１２）が挿入され、かつラック（２）の下面が支持ローラ（３）の凹凸面に支持された状態で、突き合せ部が順次プローブ（１２）を通過するように一体に移動しながら、さらに移動方向に存在する押えローラ（５）と駆動ローラ（４）との間に通されていく。
【００２３】
このように、突き合せ部が順次プローブ（１２）を通過するように両構成部材（１）（１）及びラック（２）が移動することによって、プローブ（１２）との接触部が摩擦熱にて順次軟化撹拌されて、構成部材（１）（１）は接合一体化される。すなわち、プローブ（１２）の回転により発生する摩擦熱、あるいはさらに回転子（１１）の肩部と構成部材（１）の上面との摺動に伴い発生する摩擦熱により、プローブ（１２）との接触部分近傍において構成部材（１）（１）は軟化し、かつ撹拌されるとともに、構成部材（１）（１）の移動に伴って、軟化撹拌分部がプローブ（１２）の通過溝を埋めるように塑性流動したのち、摩擦熱を急速に失って冷却固化される。この減少が構成部材（１）（１）の移動に伴って順次繰り返されていき、最終的に構成部材（１）（１）が突き合せ部において接合一体化される。
【００２４】
また、このプローブ（１２）による突き合せ部の摩擦撹拌接合の際、両構成部材（１）（１）における後述のプローブ（１２）との接触部は、自軸回転する支持ローラ（３）の周面に形成された凹凸によって、構成部材（１）（１）の厚さ方向に振動する。このため、構成部材（１）（１）の接合部であるリブ（１ｂ）（１ｂ）は、上述の摩擦撹拌接合と同時に、その上面に支持ローラ（３）の凹凸ピッチに対応したピッチを有する、波形の滑り止め用凹凸（６）が連続して形成されることになる。
【００２５】
そして、移動方向に存在する前記押えローラ（５）と駆動ローラ（４）との間に通された構成部材（１）（１）及びラック（２）が、該押えローラ（５）により駆動ローラ（４）の周面に押し付けられて、駆動ローラ（４）から駆動力が更に付与されることによって、構成部材（１）（１）の突き合せ部の接合終了位置がプローブ（１２）に接触するまで一体に移動する。構成部材（１）（１）の接合が終了したあとは、構成部材（１）（１）の突き合せ部からプローブ（１２）を抜き取り、接合装置から構成部材（１）（１）及びラック（２）を取り出して、構成部材（１）（１）とラック（２）とを分離する。
【００２６】
こうして、構成部材（１）（１）の突き合せ部が摩擦撹拌接合により接合一体化されると同時に、リブ（１ｂ）（１ｂ）の表面に滑り止め用凹凸（６）が形成されることによって、滑り止め用凹凸（６）が形成された足場材（Ａ）を簡単かつ確実に製造することができるので、構成部材（１）（１）を接合一体化したあとに別に滑り止め用凹凸（６）を形成する必要がなくなり、足場材（Ａ）の生産効率を向上させることが可能となる。
【００２７】
なお、この実施形態では、支持ロール（３）の破損防止のために、構成部材（１）（１）の下面にラック（２）を配置するもとしたが、ラック（２）を配置せずに足場材（Ａ）を製造するものとしてもよい。
【００２８】
また、構成部材（１）の幅方向の一端部にリブ（１ｂ）を垂設し、このリブ（１ｂ）の上面に滑り止め用凹凸部を形成するものとしたが、このようなリブ（１ｂ）を設けずに、構成部材（１）（１）の上面に滑り止め用凹凸を直接形成するものとしてもよい。
【００２９】
図４〜図６はこの発明の他の実施形態を示すものである。この実施形態において、図１〜図３に示したものと同一構成部分については同一の符号を付して、その説明を省略する。
【００３０】
この実施形態では、上面（プローブ１２側の面）にリブの存在しない構成部材（１０１）（１０１）を用いているとともに、構成部材（１０１）（１０１）の突き合わせ部の下側に配置された角棒状のラック（１０２）の下面には凹凸部（１０２ａ）が形成されている。
【００３１】
かつ、プローブ（１２）の下方位置には、周面に図１〜図３に示した歯車状の凹凸のない断面円形の支持ローラ（１０３）が配置されるとともに、前記支持ローラ（１０３）に対し構成部材（１０１）（１０１）の移動方向後方の位置には、前記ラック（１０２）の凹凸部（１０２ａ）と噛合する凹凸（１０４ａ）を有する歯車状の駆動ローラ（１０４）が配置されている。
【００３２】
このような構成において、駆動ローラ（１０４）が所定方向に回転すると、駆動ローラ（１０４）と噛合するラック（１０２）が前方に移動し、さらにはラック（１０２）上方の構成部材（１０１）（１０１）が移動する。
【００３３】
一方、プローブ（１２）の下方の支持ローラ（１０３）においては、図６（ａ）（ｂ）に示すように（なお、図６では、構成部材（１０１）（１０１）については図示を省略している）、回転する支持ローラ（１０３）の周面の上端部をラック（１０２）の下面の凹凸部（１０２ａ）が順に通過して行く。そして、図６（ａ）に示すように、支持ローラ（１０３）の周面の上端部にラック（１０２）の凹部（１０２ｃ）が位置したときには、ラック（１０２）の水平位置は下がり、図６（ｂ）に示すように、支持ローラ（１０３）の周面の上端部にラックの凸部（１０２ｂ）が位置したときには、ラック（１０２）の水平位置は上がり、従ってラック（１０２）の凹凸部（１０２ａ）が支持ローラ（１０３）を通過する度にラック（１０２）は上下に振動する。このため、構成部材（１）（１）の接合部には、摩擦撹拌接合と同時に、その上面にラック（１０２）の凹凸部（１０２ａ）のピッチに対応したピッチを有する、波形の滑り止め用凹凸（１０６）が連続して形成されることになる。
【００３４】
なお、以上説明した第１、第２の実施形態においては、２枚の板状の構成部材（１）（１）（１０１）（１０１）を摩擦撹拌接合により接合一体化するのに、プローブ（１２）を構成部材（１）（１）（１０１）（１０１）の長さとほぼ同じ範囲だけ移動させるものとしたが、プローブ（１２）を構成部材（１）（１）（１０１）（１０１）の長さより狭い範囲で移動させるものとしてもよい。
【００３５】
また、構成部材（１）（１０１）として押出形材を用いたが、ダイカスト材や鋳物材等を用いてもよい。
【００３６】
また、これらの実施形態では、接合部に滑り止め用凹凸が形成された足場材の製造方法について説明したが、上述の製造方法と同様の製造方法によって、接合部に装飾用凹凸が形成された装飾材を簡単かつ確実に製造することができる。
【００３７】
【発明の効果】
この発明によれば、構成部材の突き合せ部が摩擦撹拌接合により接合一体化されると同時に、構成部材の接合部に波形の凹凸が形成されるので、表面に凹凸が形成された部材を簡単かつ確実に製造することができる。従って、例えば前記部材を足場材あるいは装飾材として用いた場合、構成部材を接合一体化したあとに別に滑り止め用凹凸あるいは装飾用凹凸を形成する必要がなくなり、足場材あるいは装飾材の生産効率を向上させることが可能となる。
【図面の簡単な説明】
【図１】この発明の一実施形態を示す斜視図である。
【図２】図１のII−II線断面図であり、プローブ挿入部を模式的に示す図である。。
【図３】この発明の一実施形態における足場材の斜視図である。
【図４】この発明の他の実施形態を示す斜視図である。
【図５】図４のＶ−Ｖ線断面図である。
【図６】プローブ下方の支持ローラとラックの凹凸部との位置関係を示す断面図である。
【符号の説明】
１、１０１・・・構成部材
１ａ・・・・・・平板部
１ｂ・・・・・・リブ
２、１０２・・・ラック
１０２ａ・・・・凹凸部
３、１０３・・・支持ローラ
４、１０４・・・駆動ローラ
５・・・・・・・押えローラ
６、１０６・・・滑り止め用凹凸
１０・・・・・・接合工具
１１・・・・・・回転子
１２・・・・・・プローブ[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a member having unevenness formed at a joint portion, such as aluminum or an aluminum alloy (hereinafter referred to as aluminum), which is used for a scaffold material or a decoration material, for example.
[0002]
[Prior art and problems to be solved by the invention]
In recent years, for example, a material made of aluminum has been widely used as a scaffolding material or a decoration material because of its advantage of being suitable for mass production in addition to being lightweight and high in strength. As one method for producing such scaffolds and decorative materials, the divided structural members are butted together, and in this state, the solid-phase contact is less likely to cause heat distortion and the like with a small amount of heat input. A method of performing friction stir welding, which is one of the legal methods, has been proposed.
[0003]
By the way, in said scaffold material, in order to prevent the danger that an operator slips | slides a foot | leg, the unevenness | corrugation for a slip may be provided in the surface of a scaffold material. Moreover, in said decoration material, in order to improve a decoration effect, the unevenness | corrugation for decoration may be provided in the surface of a decoration material. However, conventionally, after the above-mentioned components are joined and integrated by friction stir welding to produce a scaffolding material or a decorative material, the surface of the scaffolding material or the decorative material is further subjected to a known process such as cutting to prevent slipping. However, there is a problem in that the productivity of the scaffolding material or the decorative material is lowered because the processing is very troublesome.
[0004]
This invention is made in view of the above-mentioned problem, and it aims at providing the manufacturing method of the member in which the unevenness | corrugation was formed in the junction part which can form an unevenness | corrugation in a junction part easily and reliably. To do.
[0005]
[Means for Solving the Problems]
In order to achieve the above object, a method of manufacturing a member having irregularities formed in a joint portion according to the present invention has a probe disposed close to a gear-shaped support roller in which irregularities are continuously formed on a peripheral surface, A state in which the constituent member arranged in the butting state is interposed between the support roller and the probe, the constituent member is supported in the thickness direction by the support roller, and the probe that rotates in the butting portion is inserted. None. In this state, the component member is moved so that the abutting portion sequentially passes the probe, and the contact portion of the component member with the probe is made thicker by the unevenness of the peripheral surface of the support roller that rotates on its own axis. By vibrating in the vertical direction, the abutting portion is sequentially softened by frictional heat with the probe and stirred to join and integrate the constituent members, and at the same time, join the constituent members. And forming continuously unevenness of waveform.
[0006]
According to this, when the friction stir welding is performed at the butt portion of the component member, the contact portion of the component member with the probe vibrates in the thickness direction of the component member due to the unevenness formed on the peripheral surface of the support roller. Therefore, it is possible to easily and surely manufacture a member in which corrugated irregularities are formed in the joint portion of the constituent member and the concave and convex portions are formed on the surface at the same time as the butted portion of the constituent member is joined and integrated by friction stir welding. it can.
[0007]
Further, according to another aspect of the present invention, there is provided a structural member in which a probe is disposed close to a support roller and arranged in a butted state and a rack having a concavo-convex portion on one side. The probe which is overlapped so that the concavo-convex portion is located on the support roller side, is interposed between the support roller and the probe, supports the component member in the thickness direction by the support roller, and rotates to the butting portion In this state, the rack and the constituent members are moved integrally so that the abutting portion sequentially passes through the probe, and the uneven portion of the rack is disposed on the peripheral surface of the supporting roller that rotates on its own axis. By passing, the contact portion of the component member with the probe is vibrated in the thickness direction of the component member, so that the butt portion is sequentially heated by frictional heat with the probe. The method of manufacturing a member having irregularities formed at the joint, wherein the corrugated irregularities are continuously formed at the joints of the constituent members at the same time as the components are joined and integrated by stirring. is there.
[0008]
Also in this manufacturing method, the contact portion with the probe in the component member vibrates in the thickness direction of the component member when the concave and convex portion of the rack passes through the peripheral surface of the support roller rotating on its own axis. At the same time, the butted portions are joined and integrated by friction stir welding, and at the same time, corrugated irregularities are formed at the joining portions of the constituent members, and a member having irregularities formed on the surface can be manufactured easily and reliably.
[0009]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the manufacturing method of the member by which the unevenness | corrugation was formed in the junction part which concerns on this invention is demonstrated with reference to one Embodiment shown in FIGS. In this embodiment, the scaffold material (A) is manufactured by butt-joining two long plate-like structural members (1) and (1).
[0010]
As shown in FIG. 1, the structural member (1) is an aluminum extrusion having a strip-shaped flat plate portion (1a) and a rib (1b) suspended along the length direction at one end of the surface in the width direction. It is made of a mold material and is in a state in which the end faces of one end in the width direction where the rib (1b) is formed are abutted with each other.
[0011]
The rib (1b) is a part where friction stir welding is performed as will be described later, and at the same time, a corrugated anti-slip unevenness (6) is formed on the upper surface thereof. The height of the rib (1b) is preferably 1/10 of the thickness of the component (1) so that the non-slip irregularities (6) are appropriately formed with respect to the component (1) (1). It should be about ½.
[0012]
Further, the component member (1) has a metal rack (2) of the same size and shape as the component members (1) and (1) in a butted state, and the peripheral portion thereof is the component member (1) (1). It arrange | positions in the aspect which makes it correspond to the peripheral part of this, and the upper surface contacts the lower surface of the said structural member (1) (1). In the rack (2), when the structural members (1) and (1) are joined and integrated as will be described later, the probe (12) of the joining tool (10) penetrates the structural members (1) and (1). It is for preventing contact with the support roll (3).
[0013]
(3) supports the constituent members (1), (1) and the rack (2) from below, and the corrugated anti-slip irregularities on the upper surfaces of the ribs (1b) (1b) of the constituent members (1) (1) ( It is a support roller for forming 6). On the peripheral surface of the support roller (3), a plurality of ridges (3a) along the length direction of the support roller (3) are continuously provided at a constant pitch in the circumferential direction. The roller (3) has a gear shape with a circumferential surface formed with irregularities. The roller length is set to be slightly longer than the sum of the widths of the constituent members (1) and (1) in the butted state, and the roller rotates in accordance with the movement of the constituent members (1) and (1) and the rack (2). ing. Thus, the component members (1) (1) and the rack (2) are moved together in a state where the back surface of the rack (2) is in contact with and supported by the protrusion (3a) of the support roller (3). Then, the contact portions of both the constituent members (1) and (1) with the probe (12), which will be described later, are formed by the concavities and convexities formed on the peripheral surface of the supporting roller (3) that rotates on its own axis. 1) Vibrates in the thickness direction. Therefore, the ribs (1b) and (1b) of the constituent members (1) and (1) have a pitch corresponding to the concave and convex pitch of the support roller (3) at the same time as the joint integration by friction stir welding as will be described later. The corrugated anti-slip irregularities (6) having the following are continuously formed. If the uneven pitch of the support roller is different, the vibration period of the contact portion between the constituent members (1) and (1) with the probe (12) is also different, and the pitch of the non-slip unevenness formed at the joint portion is also different. When it is desired to change the pitch of the anti-slip unevenness (6), it may be replaced with a support roller having a predetermined uneven pitch accordingly.
[0014]
A cylindrical rotor (11) having a large diameter and an end shaft of the rotor (11) are provided at positions where the butted portions of the two constituent members (1) and (1) pass above the support roller (3). A joining tool (10) having a pin-shaped probe (12) with a small diameter provided integrally on a wire is arranged in a manner to bring the probe (12) close to the peripheral surface of the support roller (3). ing. The joining tool (10) can rotate the probe (12) by rotating the rotor (11), and the probe (12) and the rotor (11) are composed of components ( 1) It is made of a heat-resistant material that is harder than (1) and can withstand frictional heat generated during joining. In addition, (11a) is a shoulder part which consists of a probe (12) side flat surface of a rotor (11). By arranging the support roller (3) and the probe (12) in this way, both the constituent members (1) (1) and the rack (2) are interposed between the support roller (3) and the probe (12). The probe (12) is inserted into the abutting portion of both the constituent members (1) and (1) while being supported by the support roller (3).
[0015]
Also, a cylindrical drive roller having the same diameter as the root circle of the support roller (3) is provided before and after the support roller (3) in the moving direction of both the constituent members (1) (1) and the rack (2). (4) is arranged in parallel with the support roller (3) at the same axial position as the axial position of the support roller (3). These front and rear drive rollers (4) and (4) support both the components (1) and (1) and the rack (2) together with the support roller (3), and are driven to rotate by the drive mechanism (not shown). Thus, the structural members (1) (1) and the rack (2) are moved to one side in the length direction. The drive rollers (4) and (4) have the same diameter as the root circle of the support roller (3) as described above, that is, smaller than the support roller (3) by the height of the protrusion (3a). Since the diameter is set, the contact portion of the component (1) (1) with the probe (12) bends to the probe (12) side up to the height of the protrusion (3a) of the support roller (3). Therefore, the vibration due to the unevenness of the peripheral surface of the support roller (3) is likely to occur.
[0016]
In addition, on the front and rear of the probe (12) in the moving direction of the two component members (1) and (1), a rotatable presser roller (5) having the same shape and the same dimension as the drive roller (4) and both components. It arrange | positions in the aspect which opposes the thickness direction of member (1) (1). The presser roller (5) includes a pressure mechanism (not shown), and the peripheral surfaces of the presser rollers (5) are moved to the components (1) (1) (1) (1) (1) and (2). It is designed to freely rotate its own axis while being pressed against the upper surface of 1). For this reason, the structural members (1), (1) and the rack (2) interposed between the support roller (3) and the probe (12) are pressed against the drive roller (4) by the pressing rollers (5). Thus, the driving force in the moving direction is applied integrally without causing slip. In addition, it is good also as what moves a structural member (1) (1) by pressing the longitudinal direction rear-end part of a structural member (1) (1), without using a drive roller (4).
[0017]
Next, a method for manufacturing a scaffold using the friction stir welding apparatus will be described.
[0018]
First, in a state in which the probe (12) is kept waiting at a position above the support roller (3), a peripheral portion is formed on the bottom surface of the constituent members (1) and (1) in abutting state and the constituent members (1) and (1). The rack (2) arranged so as to coincide with each other is passed between the press roller (5) and the driving roller (4) that is rotationally driven from one end in the length direction.
[0019]
The two structural members (1) (1) and the rack (2) passed between the presser roller (5) and the drive roller (4) are pressed against the peripheral surface of the drive roller (4) by the presser roller (5). As a result, a driving force is applied from the driving roller (4) that is rotationally driven, and the driving force moves integrally between the probe (12) and the support roller (3).
[0020]
When the joining start scheduled position of the butted portions of both the constituent members (1) and (1) reaches the lower position of the probe (12), the driving of the driving roller (4) is stopped to stop the constituent members (1) ( 1) Stop the rack (2). Then, when the probe (12) is lowered while being rotated and the tip of the probe (12) is brought into contact with the butted portion of the constituent members (1) and (1), the contact portion is softened by frictional heat. (12) is lowered and inserted into the abutting part, and is stopped and fixed immediately before the tip part comes into contact with the rack (2). In addition, since the rack (2) is arranged on the lower surfaces of the two component members (1) and (1), the probe (12) should pass through the butted portions of the two component members (1) and (1). However, it is possible to prevent the support roller (3) from being damaged due to contact with the support roller (3).
[0021]
Thus, the components (1), (1) and the rack (2) are interposed between the support roller (3) and the probe (12) so that the probe (12) is inserted into the abutting portion, and the rack The lower surface of (2) is brought into contact with and supported by the uneven surface of the support roller (3). The probe (12) is lowered in advance, and the probe (12) is laterally moved by forcibly passing the components (1) and (1) between the probe (12) and the support roller (3). May be inserted into the butting portion.
[0022]
Next, when the drive roller (4) is re-driven, a driving force is applied to the constituent members (1) (1) and the rack (2), and the probe (12) is applied to the butting portion of the constituent members (1) (1). ) Is inserted and the bottom surface of the rack (2) is supported by the uneven surface of the support roller (3), and the abutting portion sequentially moves so as to pass through the probe (12) and further move. It passes between the pressing roller (5) and the driving roller (4) existing in the direction.
[0023]
In this way, both the constituent members (1) (1) and the rack (2) move so that the abutting portion sequentially passes through the probe (12), so that the contact portion with the probe (12) is subjected to frictional heat. Then, the components (1) and (1) are joined and integrated. That is, the frictional heat generated by the rotation of the probe (12) or the frictional heat generated by the sliding of the shoulder of the rotor (11) and the upper surface of the component member (1) causes the contact with the probe (12). The constituent members (1) and (1) are softened and agitated in the vicinity of the contact portion, and the softened stirring portion fills the passage groove of the probe (12) as the constituent members (1) and (1) move. After the plastic flow, the frictional heat is rapidly lost to solidify by cooling. This reduction is sequentially repeated as the constituent members (1) and (1) move, and finally the constituent members (1) and (1) are joined and integrated at the abutting portion.
[0024]
Further, at the time of friction stir welding of the abutting portion by the probe (12), the contact portion with the later-described probe (12) in both the constituent members (1) and (1) is the support roller (3) rotating on its own axis. The unevenness formed on the peripheral surface vibrates in the thickness direction of the constituent members (1) and (1). For this reason, the rib (1b) (1b) which is a junction part of structural member (1) (1) has the pitch corresponding to the uneven | corrugated pitch of a support roller (3) on the upper surface simultaneously with the above-mentioned friction stir welding. The corrugated anti-slip irregularities (6) are continuously formed.
[0025]
The component members (1) (1) and the rack (2) passed between the pressing roller (5) and the driving roller (4) existing in the moving direction are driven by the pressing roller (5). When the driving force is further applied from the driving roller (4) by being pressed against the peripheral surface of (4), the joining end position of the butted portion of the constituent members (1) (1) contacts the probe (12). Move together until you do. After the joining of the constituent members (1) and (1) is completed, the probe (12) is extracted from the butted portion of the constituent members (1) and (1), and the constituent members (1) and (1) and the rack ( 2) is taken out, and the constituent members (1) (1) and the rack (2) are separated.
[0026]
Thus, the butted portions of the constituent members (1) and (1) are joined and integrated by friction stir welding, and at the same time, the non-slip irregularities (6) are formed on the surfaces of the ribs (1b) and (1b). Since the scaffold material (A) on which the anti-slip irregularities (6) are formed can be manufactured easily and reliably, the non-slip irregularities (1) and (1) are joined and integrated separately. It is not necessary to form 6), and the production efficiency of the scaffold (A) can be improved.
[0027]
In this embodiment, the rack (2) is arranged on the lower surface of the constituent members (1) (1) in order to prevent damage to the support roll (3), but the rack (2) is not arranged. It is good also as what manufactures scaffolding material (A).
[0028]
Further, the rib (1b) is vertically provided at one end portion in the width direction of the component member (1), and the non-slip uneven portion is formed on the upper surface of the rib (1b). ) May be formed directly on the upper surfaces of the constituent members (1) and (1).
[0029]
4 to 6 show another embodiment of the present invention. In this embodiment, the same components as those shown in FIGS. 1 to 3 are denoted by the same reference numerals, and the description thereof is omitted.
[0030]
In this embodiment, the constituent members (101) and (101) having no ribs are used on the upper surface (the surface on the probe 12 side), and the constituent members (101) and (101) are disposed below the butted portions. Concave and convex portions (102a) are formed on the lower surface of the square bar-shaped rack (102).
[0031]
In addition, a support roller (103) having a circular cross section with no gear-like irregularities shown in FIGS. 1 to 3 is disposed on the peripheral surface at a position below the probe (12), and the support roller (103) On the other hand, a gear-like drive roller (104) having a concavo-convex portion (104a) that meshes with a concavo-convex portion (102a) of the rack (102) is arranged at a position rearward in the movement direction of the constituent members (101) (101). Yes.
[0032]
In such a configuration, when the drive roller (104) rotates in a predetermined direction, the rack (102) meshing with the drive roller (104) moves forward, and further, the component member (101) (above the rack (102) ( 101) moves.
[0033]
On the other hand, in the support roller (103) below the probe (12), as shown in FIGS. 6 (a) and 6 (b), the components (101) and (101) are not shown in FIG. The concave and convex portions (102a) on the lower surface of the rack (102) sequentially pass through the upper end portion of the peripheral surface of the rotating support roller (103). As shown in FIG. 6A, when the concave portion (102c) of the rack (102) is located at the upper end of the peripheral surface of the support roller (103), the horizontal position of the rack (102) is lowered, and FIG. As shown in (b), when the rack protrusion (102b) is positioned at the upper end of the peripheral surface of the support roller (103), the horizontal position of the rack (102) is raised, and therefore the uneven portion of the rack (102). Each time (102a) passes through the support roller (103), the rack (102) vibrates up and down. For this reason, the joint portion of the constituent members (1) and (1) has a pitch corresponding to the pitch of the concavo-convex portion (102a) of the rack (102) on the upper surface at the same time as the friction stir welding, and is used for the anti-corrugated Concavities and convexities (106) are formed continuously.
[0034]
In the first and second embodiments described above, a probe (1), (1), (101), and (101) are joined and integrated by friction stir welding. 12) is moved by substantially the same range as the length of the constituent members (1) (1) (101) (101), but the probe (12) is moved to the constituent members (1) (1) (101) (101). It is good also as what is moved in the range narrower than this length.
[0035]
Moreover, although the extrusion shape material was used as the structural members (1) and (101), a die-cast material or a casting material may be used.
[0036]
Further, in these embodiments, the manufacturing method of the scaffold material in which the anti-slip unevenness is formed in the joint portion has been described, but the decorative unevenness is formed in the joint portion by the same manufacturing method as the above-described manufacturing method. A decorative material can be manufactured easily and reliably.
[0037]
【The invention's effect】
According to the present invention, the butt portion of the constituent member is joined and integrated by friction stir welding, and at the same time, the corrugated unevenness is formed at the joint portion of the constituent member. And it can manufacture reliably. Therefore, for example, when the member is used as a scaffolding material or a decoration material, it is not necessary to separately form an unevenness for anti-slip or an unevenness for decoration after the structural members are joined and integrated, thereby improving the production efficiency of the scaffolding material or the decoration material. It becomes possible to improve.
[Brief description of the drawings]
FIG. 1 is a perspective view showing an embodiment of the present invention.
FIG. 2 is a cross-sectional view taken along the line II-II in FIG. 1 and schematically showing a probe insertion portion. .
FIG. 3 is a perspective view of a scaffold material according to an embodiment of the present invention.
FIG. 4 is a perspective view showing another embodiment of the present invention.
5 is a cross-sectional view taken along line VV in FIG.
FIG. 6 is a cross-sectional view showing a positional relationship between a support roller below a probe and an uneven portion of a rack.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1,101 ... Constituent member 1a ... Flat plate part 1b ... Rib 2, 102 ... Rack 102a ... Uneven part 3, 103 ... Support rollers 4, 104 ... Driving roller 5 ... Presser roller 6, 106 ... Anti-slip unevenness 10 ... Joining tool 11 ... Rotor 12 ... probe

Claims

A probe (12) is arranged close to a gear-like support roller (3) having unevenness continuously formed on the peripheral surface,
The component members (1) and (1) arranged in a butted state are interposed between the support roller (3) and the probe (12), and the component members (1) and (1) are moved by the support roller (3). A state in which the probe (12) rotating in the butting portion is inserted and supported in the thickness direction,
In this state, the structural members (1) and (1) are moved so that the abutting portion sequentially passes the probe, and the structural members (1) ( By vibrating the contact portion with the probe (12) in 1) in the thickness direction of the constituent members (1) and (1),
At the same time, the butt portion is softened by frictional heat with the probe and agitated to join and integrate the constituent members (1) and (1). 6) is continuously formed, and a method for producing a member in which unevenness is formed in a joint portion.

The component (101) (101) in which the probe (12) is disposed in close proximity to the support roller (103) and the rack (102) having the concavo-convex portion (102a) on one side thereof is provided as the component (101 ) (101) and the support roller (103) and the probe (12) so that the uneven portion (102a) of the rack (102) is positioned on the support roller (103) side. And the component member (101) (101) is supported in the thickness direction by the support roller (103) and the rotating probe (12) is inserted into the butting portion.
In this state, the rack (102) and the constituent members (101) (101) are integrally moved so that the abutting portion sequentially passes the probe, and the peripheral surface of the support roller (103) rotating on its own axis is racked. By passing the concavo-convex portion (102a) of (102), the contact portion of the constituent members (101) (101) with the probe (12) is vibrated in the thickness direction of the constituent members (101) (101). By
The butt portion is sequentially softened by frictional heat with the probe and stirred to join and integrate the constituent members (101) and (101). At the same time, corrugated irregularities ( 106) is formed continuously, and the manufacturing method of the member by which the unevenness | corrugation was formed in the junction part is characterized by the above-mentioned.

The component members (1) and (1) are made of an aluminum extrusion mold material having a strip-shaped flat plate portion (1a) and a rib (1b) vertically suspended at one end of the surface in the width direction, The joint part according to claim 1 or 2, wherein the corrugated anti-slip irregularities are formed on the upper surface of the rib by joining the end faces of the one end in the width direction in which the rib (1b) is formed to face each other. The manufacturing method of the member in which the unevenness | corrugation (6) was formed in.

The height of the rib (1b) is 1/10 to 1/2 of the plate thickness of the constituent members (1) (1). A method for manufacturing the formed member.

The scaffolding material which has the unevenness | corrugation for anti-slip on the surface manufactured by the manufacturing method of any one of Claims 1-4.