JP4298784B1 - Method for manufacturing railway vehicle structure by friction stir welding - Google Patents

Abstract

A method for manufacturing a structure for a railway vehicle by friction stir welding with reduced labor is provided.
Both the first face plate 11 side and the second face plate 12 side are connected to the joining end faces 11m, 11n, 12m, and 12n made of inclined surfaces that are faced to each other between the first face plates 11 and the second face plates 12. The double skin panel 10 is fixed in a state where a load is applied in the width direction so that the gap P does not occur over the entire length, and the joint portion is sandwiched and pressed by the pair of rotating bodies 151 and 152 of the friction stir welding tool 150. A method of manufacturing a railway vehicle structure by friction stir welding in which friction stir welding is performed by a stirring shaft 153 that rotates and moves along a longitudinal direction.
[Selection] Figure 4

Description

  The present invention relates to a manufacturing method for manufacturing a structure for a railway vehicle by joining a double skin panel using a friction stir welding tool of a bobbin tool type, and in particular, there is no gap between face plates of the double skin panel. The present invention relates to a method of manufacturing a railway vehicle structure by friction stir welding.

  Double-skin panels made of aluminum alloy formed by extrusion molding are used for high-speed railway vehicles such as Shinkansen vehicles, and the structure for railway vehicles is formed by joining long double-skin panels with a certain width. Composed. In manufacturing such a structure for a railway vehicle, friction stir welding is used in which the face plates of the double skin panels that are butted in the width direction are joined together by friction stirring. For example, Patent Document 1 below describes a double-skin panel friction stir welding performed as shown in FIG. 6 (first conventional example).

  The double skin panels 100A and 100B of the same document are constituted by two parallel face plates 101 and 102 and ribs 109 connecting the both sides, and free end joints 111 and 112 protruding from the end ribs 108 are formed. ing. In the friction stir welding, both joint portions 111 and 112 of the double skin panels 100A and 100B are abutted and the face plates 101 and 102 are arranged flush with each other. And using the bobbin tool 150 which is a tool for friction stir welding, the joining parts 111 and 112 are pinched | interposed with a pair of shoulders, and joining by friction stirring is performed. At that time, the joining end surfaces of the joining portions 111 and 112 are formed orthogonal to the abutting direction, and a gap 120 may be generated during the abutting. Therefore, the junctions 111 and 112 are formed thick so that the gap 120 can be filled.

On the other hand, Patent Documents 2 and 3 below describe a friction stir welding of a double skin panel in which an end surface of a joint portion is an inclined surface. In Patent Document 2, the upper opening of the joint portion is closed with a joint plate, and the joint plate is placed and installed like a lid using the inclination of the end face, thereby making it difficult for defects due to gaps to occur. Friction stir welding (second conventional example). In Patent Document 3, the double skin panel is formed so that the joint end surface of the joint portion of the double-sided plate is inclined and one is fitted into the other. For this reason, even if the inclined joining end faces are pressed against each other by the pinching by the rotating body of the bobbin tool and a gap is formed on both surfaces, friction stir welding is performed with the gap closed (third conventional example).
Japanese Patent No. 4052443 (FIG. 1, paragraphs 0023 to 0024) Japanese Patent Laying-Open No. 2004-243379 (FIG. 6, paragraph 0047) JP 2007-283379 (FIG. 8, paragraphs 0053 to 0057)

  The double-skin panel that constitutes a railway vehicle structure has a length of, for example, 20 meters. Therefore, the joint, which is a free end having low rigidity, is slightly distorted in the thickness direction when viewed in the longitudinal direction. May have occurred. Then, as shown in FIG. 6, there are cases where the heights of both joints 111 and 112 of the double skin panels 100A and 100B are not uniform, and if the friction stir welding is performed as it is, a step remains on the finished surface. Therefore, conventionally, when performing friction stir welding, it has been necessary to find a place where a step has occurred over the entire length of 20 meters, and hitting with a hammer or the like to align the heights.

On the other hand, the third conventional example describes a joining method in which a gap is generated in the joining end face when joining the double skin panel in which the joining end face is inclined. In other words, when abutting on one face plate side to be friction stir welded, a double gap is formed with dimensions such that there is a gap between the joining end faces on the other face plate side and the opening amount is appropriate even after thermal shrinkage of one face plate. A skin panel joining method is described.
On the other hand, the present invention relates to a double-skin panel having a slanted joint end surface, a rail by friction stir welding that actively eliminates the gap between the joint end surfaces and reduces the labor of aligning the joint height. It aims at providing the manufacturing method of the structure for vehicles.

A method for manufacturing a railway vehicle structure by friction stir welding according to the present invention includes a plurality of ribs in which a pair of long first face plates and second face plates having a predetermined width constituting the railway vehicle structure are arranged in the width direction. The connected double skin panel has a joint portion at the end portion in the width direction, in which the first and second face plates extend and protrude from end ribs that are substantially orthogonal to the first and second face plates. Two double skin panels arranged in the width direction are formed on the joint end face of the portion, and are formed with joint end faces inclined in different directions from the first and second face plates at the same width direction end. The joint end surfaces inclined in the same direction are butted together, and the joint portion of both double skin panels is sandwiched by a pair of rotating bodies of a friction stir welding tool having a bobbin tool type, and the stirring shaft between the rotating bodies Junction end The joined portions that are brought into contact with each other are frictionally agitated and joined along the longitudinal direction, and the joined portions of the first face plates and the second face plates are joined to the first face plate side over the entire length of the double skin panel. In order to prevent a gap on both the second face plate side and the first face plate side and the second face plate side, if there is a gap on the one face portion, the gap on the one face portion is eliminated. In the other joint part, the double skin panel is fixed in a state where a load is applied in the width direction so that the joint part slid between the joint end faces is deformed in the thickness direction of the face plate, and the joint part is rubbed. holding down across the pair of rotating bodies of stir welding tool, when joined with stirring by friction stir shaft rotated moves along the longitudinal direction, the joint portion towards the deformation of the plate thickness direction is generated, A pair of rotating bodies of serial friction stir welding tool, characterized in that as press down with a load of magnitude return the deformation.

According to the present invention, since the double skin panel is fixed by applying a load in the width direction, the distortion in the same direction is corrected by the component force in the plate thickness direction due to the inclined surface of the joint end surface, so the troublesome correction that has been performed conventionally Work can be omitted.
In addition, since it is pressed down with a bobbin tool so as to return the deformation of the joint at the time of friction stir welding, it is possible to perform joining with a good finish.

  Next, an embodiment of a method for manufacturing a railway vehicle structure by friction stir welding according to the present invention will be described below with reference to the drawings. First, FIG. 1 is a perspective view showing a part of a railway vehicle structure. The railcar structure 80 is configured by joining a side structure 81, a roof structure 82, and a frame 83 in the circumferential direction, and a wife structure 84 at the end in the longitudinal direction. For example, the long double skin panel 10 having a predetermined width is abutted in the width direction (circumferential direction) and joined to the side structure 81 and the roof structure 82. For the joining, the joining end faces of the adjacent double skin panels 10 are abutted, and friction stir welding is performed for a distance of 20 to 25 m which is the vehicle body length.

  FIG. 2 is a perspective view showing a joining method of the double skin panel 10. The friction stir welding apparatus for joining the double skin panels 10 has a gantry 1 formed according to the panel length, and a pressing jig 2 and a positioning block 3 for bringing the double skin panel 10 into contact therewith. A plurality of sets are provided. The positioning block 3 is a trapezoidal block body, and is fixed to the gantry 1 so as to receive the double skin panel 10 in a vertical plane. On the other hand, the pressing jig 2 includes a support block 21 fixed to the gantry 1, an adjustment rod 22 screwed into the support block 21, and a pressing block 23 connected to the adjustment rod 22 and facing the positioning block 3. It is configured. The friction stir welding apparatus (not shown) is provided with a bobbin tool that performs friction stirring along the joining line S of the double skin panel 10.

  Next, FIG. 3 to FIG. 5 are views showing a joining process of the double skin panel 10 performed by the manufacturing method of the present embodiment. Each figure shows the end surface in the longitudinal direction of the double skin panel 10, FIG. 3 shows a state where the double skin panel 10 is installed on the gantry 1, FIG. 4 shows a pressing state between the double skin panels 10, and FIG. The state which is performing friction stirring is shown.

  In the double skin panel 10 of the present embodiment, the first face plate 11 and the second face plate 12 are arranged at a certain distance so as to be substantially parallel when placed horizontally as shown in FIGS. The two side plates 11 and 12 are connected by a plurality of ribs 13 arranged in the width direction (left and right direction in the drawing) so as to connect the both side plates 11 and 12. The double skin panel 10 is a hollow extruded shape formed by extrusion molding of an aluminum material, and its extrusion direction (direction passing through the drawing of FIG. 3) is the longitudinal direction of the panel, and a direction perpendicular to the direction (FIG. 3). Is the width direction.

  The plurality of ribs 13 provided between the first and second face plates 11 and 12 are arranged so as to incline so that adjacent ones alternately change the inclination. The ribs 13 a are arranged so as to be orthogonal to the first and second face plates 11 and 12. And the 1st face plate 11 and the 2nd face plate 12 protrude in the width direction from the edge part rib 13a, and joining part 11a, 11b and 12a, 12b of a free end are formed. Here, the joint portions 11a and 12a are formed at the right end of the double skin panel 10 in the width direction, and the joint portions 11b and 12b are formed at the left end of the same double skin panel 10 in the width direction. Is. Accordingly, the left and right end portions of the double skin panel 10 are joints that can be joined to each other, whereby the double skin panels 10 arranged in the width direction can be joined together.

  As shown in FIG. 5, the joint portions 11a, 11b, 12a, and 12b are projection amounts from the end ribs 13a that allow a space for the rotating body of the bobbin tool 150 to enter. And the joining end surface of the front-end | tip is an inclined inclined surface. That is, the joint end surfaces 11m and 12m of the joint portions 11a and 12a at the right end of the double skin panel 10 are inclined inwardly facing each other, and the joint end surfaces 11n and 12n of the joint portions 11b and 12b at the left end are , Are formed to be inclined outwardly facing each other. Accordingly, the double skin panel 10 is configured such that the joint end faces 11n and 12n enter and fit into the joint end faces 11m and 12m.

  The manufacturing method of this embodiment is a method of connecting the double skin panels 10 constituting such a railway vehicle structure by friction stir welding. As shown in FIG. 2, the double skin panel 10, which is adjacent to each other constituting the railcar structure, is installed on the gantry 1, the positioning block 3 is applied to one end, and the other end is pressed. Fixing by applying a load by the jig 2 is performed. The double skin panel 10 to be joined is fixed at several places over the entire length of about 20 meters by the positioning block 3 and the pressing jig 2.

  At this time, in the pair of double skin panels 10, the joint portions 11 a and 11 b of the first face plate 11 and the joint portions 12 a and 12 b of the second face plate 12 protrude from the joint end surfaces 11 m and 11 n and the joint end surfaces 12 m and 12 n. Are combined. However, in all cases, the joining end faces are not always abutted cleanly. For example, as shown in FIG. 3, due to a manufacturing error of the double skin panel 10, in the joining portions 12 a and 12 b of the second face plate 12, A gap P may occur between the joint end faces 12m and 12n. In such a case, in the third conventional example given in the background art section, a method of allowing the gap is taken, but in this embodiment, the double skin panels 10 are pressed to each other until the gap P is eliminated. 2 is used.

  Therefore, the double skin panel 10 is pressed with a predetermined load so as to close and eliminate the gap P. The adjustment of the pressing force by each pressing jig 2 is performed so that the gap P is eliminated over both the first face plate 11 and the second face plate 12 over the entire length of the double skin panel 10. By the way, when both the first face plate 11 and the second face plate 12 are pressed so as to eliminate the gaps, for example, as shown in FIG. The joint end surfaces 11m and 11n slide on each other's inclined surfaces, and deformation occurs in the plate thickness direction (vertical direction in the drawing) as indicated by arrows. However, the deformation of the gap P shown in FIG. 3 and the joint portions 11a and 11b shown in FIG. 4 are exaggerated so that the state is easy to understand, and actually the gap interval and the deformation amount are not so much. , Very small.

  Since the double skin panel 10 has a length of about 20 meters, the joints 11a, 11b, 12a, and 12b having relatively low rigidity are slightly distorted in the thickness direction when viewed in the longitudinal direction. May have occurred. For this reason, depending on the joint location, the joint portions 11a and 11b and the joint portions 12a and 12b may have different heights. That is, the joining end surfaces 11 n and 12 n of one double skin panel 10 enter inside the joining end surfaces 11 m and 12 m of the other double skin panel 10. Therefore, when such joint end surfaces are engaged with each other, the pressing force acting in the width direction acts as a component force in the plate thickness direction on the joint portions 11a and 11b and the like via the inclined joint end surfaces 11m and 11n.

Since the joint portions 11a, 11b, 12a, and 12b are originally formed on the extensions of the first face plate 11 and the second face plate 12, the joint end face can be corrected by correcting the distortion that occurs when undulating when viewed in the longitudinal direction. Positions such as 11m and 11n are also aligned with the heights of the first face plate 11 and the second face plate 12. Therefore, in this embodiment, the joint part of the double skin panels 10 is pressed and abutted in the width direction. And, instead of simply abutting the joining end faces, one is to eliminate the gap P when the gap P is generated, and the other is in the plate thickness direction due to the slope of the joining end face. The purpose is to correct the distortion in the same direction by the component force. Therefore, the pressing force is set to a size that can achieve the two purposes.

  After the double skin panel 10 is fixed by the pressing jig 2, friction stir welding by the bobbin tool 150 is performed. In FIG. 5, the first face plate 11 and the second face plate 12 are expressed to be performed at the same time, but in actuality, a double skin panel 10 is fixed as shown in FIG. Joining on the first face plate 11 side is performed, and then the second face plate 12 side that is inverted and positioned above is joined. Depending on how the double skin panel 10 is fixed, the first face plate 11 and the second face plate 12 may be simultaneously performed as shown in FIG.

  The bobbin tool 150 for performing friction stir welding includes a first rotating body 151 and a second rotating body 152, and a stirring shaft 153 positioned therebetween, and rotates to the rotating bodies 151 and 152 and the stirring shaft 153 by driving a motor. Is configured to be given. The space | interval of the 1st rotary body 151 and the 2nd rotary body 152 can be adjusted now, and it can pinch | join the junction parts 11a and 11b etc. with a predetermined load.

  Therefore, as shown in FIG. 5, the bobbin tool 150 is arranged so that the stirring shaft 153 overlaps the contact position (joint portion) of the joining end faces 11m and 11n, and the first and second rotating bodies 151 and 152 are used. The joint portions 11a and 11b are sandwiched. Then, the bobbin tool 150 moves along the joining line S shown in FIG. 2 while rotating, so that the stirring shaft 153 frictionally stirs the contact portion of the joining end faces 11m and 11n, and the surrounding material is plastically flowed. Make it. At that time, the first and second rotating bodies 151 and 152 holding the joint portions 11a and 11b prevent the material from being lost from the plastic zone. The softened material is plastically fluidized and stirred and kneaded, flows behind the stirring shaft 153, and the plastic materials mixed with each other lose the frictional heat and rapidly cool and solidify to complete the joining.

  By the way, in order to hold down the double skin panels 10 in the width direction without gaps, the joint portions 11a and 11b are deformed by climbing on each other in the direction indicated by the arrows as seen on the first face plate 11 side in FIG. D may be generated. However, the protruding amount of the stepped portion D in the thickness direction is small. At the time of friction stirring, the first and second rotating bodies 151 and 152 sandwiching the joint portions 11a and 11b are pressed from above and below with a load large enough to restore the deformation of the stepped portion D. Therefore, while the bobbin tool 150 is performing frictional stirring along the joining line S, the stepped portion D is deformed by being pressed by the first and second rotating bodies 151 and 152 and is stirred with other portions by frictional stirring. Kneaded and flows. Since the joint portions 11a and 11b are at the same height in the first place, there is no step in the joint portion after the bobbin tool 150 has passed, and burrs and the like due to extra material are hardly caused.

After the friction stir welding on the first face plate 11 side is completed, the double skin panel 10 is turned upside down and fixed on the gantry 1 with the second face plate 12 side up. The bobbin tool 150 sandwiches the joint portions 12a and 12b with the pair of first and second rotating bodies 151 and 152, and moves along the joint line S while rotating, whereby the stirring shaft 153 is joined to the joint end surfaces 12m and 12n. The abutting portions of the two are joined by friction stirring. Even on the second face plate 12 side, even if there is a stepped portion D where the joint portions 12a and 12b ride on each other, the stepped portion D is pressed by the first and second rotating bodies 151 and 152. Thus, the friction stir welding is performed while returning the deformation of the portion.

In the method for manufacturing a railway vehicle structure by friction stir welding according to the present embodiment, the double skin panels 10 are pressed against each other with a predetermined load in the width direction by the pressing jig 2, thereby eliminating the gap P and joining the joining end faces. Correct the distortion in the thickness direction occurring in the part. Therefore, it is possible to obtain a bonded surface with a good finish without causing the material to flow into the gap P and causing a dent after bonding. Conventionally, it has been necessary to search for a stepped portion caused by distortion in the thickness direction and correct it by striking it with a hammer. However, according to the present embodiment, such troublesome work can be omitted.
Furthermore, according to the present embodiment, when the double skin panel 10 is pressed so as to eliminate the gap P on the one face plate side, a stepped portion D is formed in which a sloped surface is ridden on the joint portion on the other face plate side. By pressing down with the bobbin tool 150, it is possible to return the deformation and perform bonding with good finish.

As mentioned above, although one embodiment was described about the manufacturing method of the structure for rail vehicles by the friction stir welding concerning the present invention, the present invention is not limited to this, but various changes are possible in the range which does not deviate from the meaning. is there.
In the above-described embodiment, the first and second face plates 11 and 12 have been described by taking the double skin panel 10 as an example, but the double skin panel 10 is, for example, curved ones constituting a roof structure or curved ones. May be joined to a flat one.

It is the perspective view which showed a part of railway vehicle structure. It is the perspective view shown about the joining method of the double skin panel. It is the longitudinal direction end surface of a double skin panel, Comprising: It is the figure which showed the state installed on the mount frame. It is the longitudinal direction end surface of a double skin panel, Comprising: It is the figure which showed the state which pressed the double skin panels in the width direction. It is the figure which showed the state which is a longitudinal direction end surface of a double skin panel, and is performing friction stirring. It is the figure shown about the joining method of the conventional double skin panel.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Base 2 Pressing jig 3 Positioning block 10 Double skin panel 11 1st face plate 12 2nd face plate 13 Rib 11a, 11b, 12a, 12b Joint part 11m, 11n, 12m, 12n Joint end surface 13a End part rib 150 Bobbin tool 151 First rotating body 152 Second rotating body 153 Stirring shaft P Clearance

Claims (1)

A double skin panel in which a pair of long first face plates having a predetermined width and a second face plate constituting a railway vehicle structure are connected by a plurality of ribs arranged in the width direction is disposed at an end in the width direction and the first And the first and second face plates extend and project from end ribs substantially orthogonal to the second face plate, and the joint end faces of the joint portions have the first and second ends at the same widthwise end. A joining end face inclined in a different direction from the second face plate is formed,
For the two double skin panels arranged in the width direction, the joint end surfaces inclined in the same direction are brought into contact with each other, and the joint portions of both double skin panels are formed by a pair of rotating bodies of a friction stir welding tool having a bobbin tool type. In the manufacturing method of a railway vehicle structure by friction stir welding, the joint portion where the joint end surfaces are butted together by the stirring shaft between the rotating bodies is frictionally stirred along the longitudinal direction.
In order to prevent a gap from being formed on both the first face plate side and the second face plate side over the entire length of the double skin panel, the first face plate side of the joint portion between the first face plates and the second face plates When there is a gap in one of the joint portions on the second face plate side, the gap in the one joint portion is eliminated, and the joint portion in which the joint end faces are slid in the other joint portion in the thickness direction of the face plate. Fix the double skin panel with a load applied in the width direction so as to cause deformation,
The joint where the deformation in the plate thickness direction occurs when the joint portion is sandwiched and pressed by a pair of rotating bodies of the friction stir welding tool, and friction stir by the stirring shaft that rotates and moves along the longitudinal direction. In the part, a method for manufacturing a railway vehicle structure by friction stir welding , wherein the pair of rotating bodies of the friction stir welding tool is pressed by a load large enough to restore the deformation .

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