JP6739795B2 - Metal component manufacturing method and metal component manufacturing apparatus - Google Patents

Description

The present invention relates to a manufacturing method or a manufacturing apparatus for manufacturing a metal component to be mounted on a vehicle from two panel-shaped metal bodies, for example.

Conventionally, for example, the insulator disclosed in Patent Document 1 is arranged between the lower surface of the floor pan and the muffler in the lower part of the vehicle for the purpose of soundproofing and heat insulation. The insulator is a panel-shaped first metal body made of an aluminum alloy material, a sheet-shaped sound absorbing heat shield disposed on the floor pan side of the first metal body, and a floor pan side of the sound absorbing heat shield. A film-shaped second metal body made of an aluminum alloy material disposed in the outer peripheral portion of the first metal body, and the outer peripheral portion of the sound absorbing and heat insulating body and the second metal body at the folded back portion. The first metal body, the sound absorbing and heat insulating body, and the second metal body are integrated by simultaneously sandwiching the outer peripheral portion of the first metal body and the outer peripheral portion of.

By the way, in the insulator as in Patent Document 1, the outer peripheral portion of the first metal body and the outer peripheral portion of the second metal body are joined to each other without folding back the outer peripheral portion of the first metal body for the purpose of improving the material yield and reducing the weight. By doing so, there is a demand to integrate the first metal body and the second metal body, and as a joining method therefor, it is possible to apply an ultrasonic joining method that is unlikely to be affected by thermal strain in the appearance of the completed insulator. Conceivable.

Japanese Patent Publication No. 2006-519710

However, in the ultrasonic bonding method, since minute vibration is applied to the bonding portion at the time of bonding, the ultrasonic wave is applied to a portion having high rigidity such as around a reference hole for positioning with respect to a jig in the metal body to be bonded. When the vibration propagates, a load may be repeatedly applied to the location, causing cracks or fractures.

The present invention has been made in view of the above point, and an object thereof is to obtain a metal component free from cracks and cracks by integrating two panel-shaped metal bodies by ultrasonic bonding.

In order to achieve the above-mentioned object, the present invention is characterized in that a reference pin for positioning a jig used when performing ultrasonic bonding can vibrate.

That is, in the first aspect of the present invention, ultrasonic bonding is possible with a jig having a jig main body installed on the floor, a plurality of reference pins, and a pin attaching means for vibrating the reference pins to the jig main body. the fitting of such a step of preparing an ultrasonic bonding means, each said respective reference pins into a corresponding plurality of two panel-like metal body the respective reference pins fitting hole is formed in the above respective metal bodies The step of placing each of the metal bodies in order on the jig body so as to fit into the hole, and the formation of a joint by the ultrasonic joining means in the overlapping portion of each of the metal bodies to integrate them. A step of obtaining a metal part, wherein each of the reference pins extends diagonally in the vertical direction, and the step of mounting each of the metal bodies on the jig body includes It is characterized in that it is a step of fitting the fitting holes into the reference pins in an obliquely extended state .

Also, the present invention comprises a jig having a jig body and a plurality of reference pins installed in the floor, are arranged on the side of the jig, and an ultrasonic bonding means capable ultrasonic bonding, Two panel-shaped metal bodies, each of which has a plurality of fitting holes corresponding to the respective reference pins, are attached to the metal bodies so that the reference pins fit into the respective fitting holes of the metal bodies. A metal component manufacturing apparatus configured to obtain a metal component integrally by forming a bonding portion by the ultrasonic bonding means in an overlapping portion of each metal body in a state of being placed on the jig main body in order. The following solution measures were taken.

That is, in the second aspect of the invention, the jig body includes pin mounting means for vibrating the reference pins to the jig body, and the reference pins are arranged so as to extend obliquely in the vertical direction. It is characterized by being.

In the first and second inventions, the two metal bodies are placed on the jig body in order so that the reference pins fit into the fitting holes of the metal bodies. When ultrasonic bonding is performed on the overlapped portions by ultrasonic bonding means, fine vibration propagates to the entire area of each metal body, and the pin mounting means vibrates in accordance with the vibration. Therefore, the two metal bodies placed on the jig vibrate in synchronism with the ultrasonic vibration, and it becomes difficult to repeatedly apply a load to the high-rigidity portions of the two metal bodies and cracks or cracks are generated. Occurrence can be suppressed .

It is a perspective view of the insulator manufactured with the manufacturing device concerning the embodiment of the present invention. It is sectional drawing in the II-II line of FIG. It is a schematic diagram of a manufacturing device concerning an embodiment of the present invention, and shows the state where two metal bodies and a sound absorption heat shield were placed on a jig used when manufacturing an insulator. FIG. 4 is an enlarged view of a IV part in FIG. 3.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. It should be noted that the following description of the preferred embodiments is merely exemplary in nature.

1 and 2 show an insulator 1 (metal part) according to an embodiment of the present invention. The insulator 1 is attached to the lower surface of the floor pan F1 of the vehicle for the purpose of heat insulation and sound insulation against heat and noise generated from exhaust system components and drive system components, and the insulator manufacturing apparatus shown in FIGS. It is manufactured by 10 (metal part manufacturing apparatus).

As shown in FIGS. 1 and 2, the insulator 1 includes a first metal body 2 made of a panel-shaped aluminum alloy material extending in the vehicle front-rear direction, and a panel surface of the first metal body 2 on the floor pan F1 side. A sheet-shaped glass wool material 3 (sound-insulating and heat-insulating body) arranged along the glass wool material 3, and a second metal body 4 made of a panel-shaped aluminum alloy material provided on the floor pan F1 side of the glass wool material 3, The second metal body 4 is assembled to the first metal body 2 so as to cover the glass wool material 3. The plate thicknesses of the first and second metal bodies 2 and 4 in FIGS. 1 to 4 are exaggerated for convenience.

The first metal body 2 has a plate thickness of 0.4 to 0.6 mm and is obtained by press-molding an aluminum alloy plate in the 1000 to 3000 range, and has a horizontal plane portion 21 extending in the vehicle front-rear direction. And a pair of inclined surface portions 22 that gradually incline so as to be located downward from both sides in the vehicle width direction of the horizontal plane portion 21 toward both ends in the vehicle width direction.

On each of the inclined surface portions 22, a pair of first seat surface portions 22a, which are circular in a plan view and projecting upward and extending horizontally, are formed at predetermined intervals in the vehicle front-rear direction. A first fitting hole 22b is formed through the center of the first seat surface portion 22a.

A portion of the first metal body 2 outside the four first seat surface portions 22a is provided with a polymerized portion 2b which overlaps with the second metal body 4 when the second metal body 4 is assembled. A large number of through holes 2c are formed in the portion of the metal body 2 surrounded by the four first seat surface portions 22a.

The second metal body 4 has a plate thickness of 0.4 to 0.6 mm and is obtained by press-molding an aluminum alloy plate in the 1000 to 3000 range, and is a horizontal panel portion extending in the vehicle front-rear direction. 41 and a pair of inclined panel portions 42 that are inclined so as to be gradually positioned downward as they approach both ends in the vehicle width direction from both sides in the vehicle width direction of the horizontal panel portion 41.

In each of the inclined panel portions 42, a second seat surface portion 42a, which is circular in a plan view and extends upward and extends horizontally, corresponds to each first seat surface portion 22a of the first metal body 2. A second fitting hole 42b is formed through the center of each of the second seat surface portions 42a.

A portion of the second metal body 4 outside the four second seat surface portions 42a is provided with a polymerized portion 4b which overlaps the polymerized portion 2b when assembled to the first metal body 2, and the second metal body is provided. A space forming portion 4a is formed in a portion surrounded by the four second seat surface portions 42a in 4 so as to project above the overlapping portion 4b in a step shape.

When the second metal body 4 is assembled to the first metal body 2, the polymerized portion 2b of the first metal body 2 and the polymerized portion 4b of the second metal body 4 overlap each other, and the first metal body 2 An accommodation space layer S1 for accommodating the glass wool material 3 is formed between the space 2 and the space forming portion 4a of the second metal body 4.

Further, between the polymerized portion 2b of the first metal body 2 and the polymerized portion 4b of the second metal body 4, the polymerized portion 2b of the first metal body 2 and the polymerized portion 4b of the second metal body 4 are provided. A plurality of solid-phase joints W1 connecting by ultrasonic bonding are formed intermittently along the outer peripheral portions of the first and second metal bodies 2 and 4, and each solid-phase joint W1 The first metal body 2 and the second metal body 4 are integrated.

As shown in FIG. 3, the insulator manufacturing apparatus 10 includes a jig 5 for positioning the second metal body 4 with respect to the first metal body 2, and a jig 5 arranged laterally of the jig 5 for ultrasonic bonding. The ultrasonic bonding machine 6 (ultrasonic bonding means) capable of

The jig 5 includes a jig body 51 installed on the floor, and the jig body 51 can be moved by a moving means (not shown).

The jig body 51 includes a thick rectangular plate-shaped base plate 52 and four support frames 53 protruding from the upper surface of the base plate 52.

These four support frames 53 are in a positional relationship of forming a rectangular vertex in a plan view, and the two support frames 53 on the side closer to the ultrasonic bonding machine 6 are on the side far from the ultrasonic bonding machine 6. The protruding height is lower than that of the two support frames 53.

Positioning units 54 are attached to the upper portions of the respective support frames 53.

As shown in FIG. 4, the positioning unit 54 includes a metal unit body 55 in which a housing recess 55a that opens obliquely upward on the ultrasonic bonding machine 6 side is formed, and approximately half the bottom surface side of the housing recess 55a. An elastic body 56 (pin positioning means) made of a hard rubber material in a ring shape is fitted in.

The accommodating recess 55a accommodates a reference pin 57 including a disk-shaped head portion 57a and a shaft portion 57b continuous with the head portion 57a, and the head portion 57a is oriented with the shaft portion 57b facing upward. Fits inside the elastic body 56, and the shaft 57b projects outward from the opening of the housing recess 55a.

That is, the elastic body 56 is configured to attach the reference pin 57 to the jig body 51 so that the reference pin 57 can vibrate.

Further, a ring member 58 having an insertion hole 58a in the center is fitted in the opening half of the accommodation recess 55a so as to contact the elastic body 56, and the shaft portion of the reference pin 57 is inserted into the insertion hole 58a. 57b is loosely fitted.

Then, the second metal body 4 is inserted so that the reference pins 57 are fitted in the second fitting holes 42b in a posture in which the side of the second metal body 4 to be assembled to the first metal body 2 faces upward. The glass wool material 3 is placed on the jig body 51 and the space forming portion 4a of the second metal body 4, and the side of the first metal body 2 to which the second metal body 4 is attached is By placing the first metal body 2 on the jig body 51 so that the reference pins 57 are fitted in the first fitting holes 22b in a downward posture, The first and second metal bodies 2 and 4 are positioned in a state where the overlapped portion 2b and the overlapped portion 4b of the second metal body 4 overlap each other.

As shown in FIG. 3, the ultrasonic bonding machine 6 includes a pedestal portion 61 capable of supporting both overlapping portions 2b and 4b of the first and second metal bodies 2 and 4 positioned on the jig 5, A vibrating portion 62 disposed above the pedestal portion 61 and capable of ultrasonic vibration, and a pressure for lowering the vibrating portion 62 and sandwiching the overlapping portions 2b and 4b between the pedestal portion 61 to apply pressure. And the pressure applying portion 63 presses the overlapping portions 2b and 4b between the pressing portion 63 and the pedestal portion 61. The solid-phase junction W1 is formed between 2b and 4b.

Then, the ultrasonic bonding machine 6 moves the jig main body 51 by a moving means (not shown), and the overlapping portions 2b of the first and second metal bodies 2 and 4 positioned by the jig main body 51. By intermittently joining 4b along the outer peripheral portions of the first and second metal bodies 2 and 4, the first and second metal bodies 2 and 4 are integrated to obtain the insulator 1.

Next, manufacturing of the insulator 1 using the insulator manufacturing apparatus 10 according to the embodiment of the present invention will be described in detail.

First, as shown in FIG. 3, the reference pins 57 are fitted in the second fitting holes 42b in a posture in which the side of the second metal body 4 to be assembled to the first metal body 2 is oriented upward. The second metal body 4 is placed on the jig body 51.

Next, the sheet-shaped glass wool material 3 is placed on the space forming portion 4a of the second metal body 4 placed on the jig body 51.

Then, the first metal body 2 is fitted such that the reference pins 57 are fitted in the first fitting holes 22b in a posture in which the side of the first metal body 2 to which the second metal body 4 is attached faces downward. Is placed on the jig body 51. Then, the overlapped portion 2b of the first metal body 2 and the overlapped portion 4b of the second metal body 4 overlap each other, and between the space forming portion 4a of the first metal body 2 and the second metal body 4. The accommodation space layer S1 is formed, and the glass wool material 3 is accommodated in the accommodation space layer S1.

Thereafter, while moving the jig body 51 by a moving means (not shown), the ultrasonic bonding machine 6 moves the overlapping portions 2b and 4b of the first and second metal bodies 2 and 4 positioned by the jig body 51. The insulator 1 is obtained by integrating the first and second metal bodies 2 and 4 by performing ultrasonic bonding intermittently along the outer peripheral portions of the first and second metal bodies 2 and 4.

The joining conditions for ultrasonic joining were: vibration frequency: 20 kHz, amplitude of the vibrating part 62: 0.06 mm, and pressure applied by the pressurizing part 63: 1.5 kN.

As described above, according to the embodiment of the present invention, when ultrasonic bonding is performed on both the overlapping portions 2b and 4b, fine vibration propagates to the entire area of the first and second metal bodies 2 and 4, but At the same time, the elastic bodies 56 are vibrated. Therefore, the first and second metal bodies 2 and 4 placed on the jig 5 vibrate in synchronization with the ultrasonic vibration, and the rigidity of the first and second metal bodies 2 and 4 is high. Since it is difficult to apply a repeated load to the location, it is possible to suppress the occurrence of cracks or fractures in the first and second metal bodies 2 and 4.

Further, since each elastic body 56 is formed of a hard rubber material, the reference pin 57 can vibrate corresponding to ultrasonic vibration with a simple structure, and the insulator 1 can be manufactured by ultrasonic bonding at low cost. It can be done in the device.

In the embodiment of the present invention, when the first and second metal bodies 2 and 4 are positioned on the jig body 51, the first fitting holes 22b and the first and second metal bodies 2 and 4 of the first and second metal bodies 2 and 4 are positioned. Although the configuration is such that each reference pin 57 is simply fitted into the two fitting holes 42b, the surroundings of each first fitting hole 22b of the first metal body 2 are pressed by the claw members of the clamp mechanism. Good.

Further, in the embodiment of the present invention, the elastic body 56 is made of a hard rubber material, but the elastic body 56 is not limited to this, and may be, for example, a foam body.

In addition, each of the joints to be applied to the overlapping portions 2b and 4b of the first and second metal bodies 2 and 4 is moved to a different jig 5 in the middle of each joint. After mounting, the remaining bonding may be performed.

In addition, each of the joints to be applied to the overlapping portions 2b and 4b of the first and second metal bodies 2 and 4 is provided with a mechanism capable of changing the positioning posture provided on the jig 5 in the middle of each joint, or The industrial robot may change the postures of the first and second metal bodies 2 and 4 by changing the inclination of the jig 5 itself, and then perform the remaining joining.

Further, in the embodiment of the present invention, the insulator 1 is manufactured from the first metal body 2, the glass wool material 3 and the second metal body 4 by the manufacturing method of the present invention, but the manufacturing method of the present invention is not limited to this. It is also possible to obtain another metal part by integrating two metal bodies having a panel shape.

INDUSTRIAL APPLICABILITY The present invention is suitable for, for example, a manufacturing method or a manufacturing apparatus when manufacturing a metal component to be assembled in a vehicle from two panel-shaped metal bodies.

1 insulator (metal parts)
2 1st metal body 4 2nd metal body 5 Jig 6 Ultrasonic bonding machine (ultrasonic bonding means)
22b First fitting hole 42b Second fitting hole 51 Jig body 56 Elastic body (pin attachment means)
57 Reference Pin W1 Joint

Claims (2)

Prepare a jig that has a jig body installed on the floor, a plurality of reference pins, and a pin attachment means that attaches the reference pins to the jig body so that they can vibrate, and an ultrasonic joining means that enables ultrasonic joining. The process of
Two panel-shaped metal bodies, each of which has a plurality of fitting holes corresponding to the reference pins, are attached to the metal bodies so that the reference pins fit into the fitting holes of the metal bodies. Steps of sequentially mounting the jig body ,
A step of obtaining a metal part integrally by forming a joint portion by the ultrasonic joining means in the overlapping portion of each metal body ,
Each of the above reference pins extends diagonally in the vertical direction,
The step of placing the metal bodies on the jig body is a step of fitting the fitting holes into the reference pins in a state where the fitting holes extend obliquely in the vertical direction. And a method for manufacturing a metal component. A jig having a jig body and a plurality of reference pins installed on the floor,
An ultrasonic bonding means that is arranged on the side of the jig and is capable of ultrasonic bonding,
Two panel-shaped metal bodies, each of which has a plurality of fitting holes corresponding to the reference pins, are attached to the metal bodies so that the reference pins fit into the fitting holes of the metal bodies. A metal component manufacturing apparatus configured to obtain a metal component integrally by forming a bonding portion by the ultrasonic bonding means in an overlapping portion of each metal body in a state of being placed on the jig main body in order. There
It said jig body is e Bei the pin mounting means for mounting the vibratably said jig body to the respective reference pin,
The metal part manufacturing apparatus , wherein each of the reference pins is arranged so as to extend obliquely in the vertical direction .

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