JP7472623B2 - Aluminum case and method for manufacturing the aluminum case - Google Patents

Aluminum case and method for manufacturing the aluminum case Download PDF

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JP7472623B2
JP7472623B2 JP2020075577A JP2020075577A JP7472623B2 JP 7472623 B2 JP7472623 B2 JP 7472623B2 JP 2020075577 A JP2020075577 A JP 2020075577A JP 2020075577 A JP2020075577 A JP 2020075577A JP 7472623 B2 JP7472623 B2 JP 7472623B2
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cast
joint
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aluminum case
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輝史 小林
雅宣 村瀬
弘典 小林
守 本田
善範 徳田
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Aisin Corp
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Description

本発明は、アルミケース及びアルミケースの製造方法に関する。 The present invention relates to an aluminum case and a method for manufacturing an aluminum case.

近年、軽量、非磁性、良熱伝導性等の利点から、アルミニウム又はその合金の鋳物を用いて製作されたアルミケースが汎用されている。特許文献1には、こうしたアルミケースの一例としてトランスミッションケース(鋳造ケース)が示されている。 In recent years, aluminum cases made from castings of aluminum or its alloys have come into widespread use due to their advantages of being lightweight, non-magnetic, and having good thermal conductivity. Patent Document 1 shows a transmission case (cast case) as an example of such an aluminum case.

アルミケースを構成するアルミニウム部材は、鋳造時において厚肉部に鋳巣等の鋳造欠陥(以下、単に鋳巣ともいう)が発生し易い。特許文献1に示される鋳造ケースでは、鋳巣の発生を抑制するために、ケースの外面の厚肉部に凹み形状の鋳抜き部分(特許文献1では肉抜き部)が設けられている。 The aluminum members that make up the aluminum case are prone to casting defects such as blowholes (hereinafter simply referred to as blowholes) in the thick parts during casting. In the cast case shown in Patent Document 1, a recessed cast-out portion (referred to as a hollowed-out portion in Patent Document 1) is provided in the thick parts of the outer surface of the case to prevent the occurrence of blowholes.

アルミケースは複数のアルミニウム製の部材を接合して製造することがある。特許文献2には、アルミニウム製の板状部材を摩擦攪拌接合法によって接合する構成が示されている。 Aluminum cases are sometimes manufactured by joining multiple aluminum members together. Patent Document 2 shows a configuration in which aluminum plate members are joined by friction stir welding.

特開2005-59082号公報JP 2005-59082 A 特開平10-263852号公報Japanese Patent Application Laid-Open No. 10-263852

アルミケースを製造するために用いられる摩擦攪拌接合法では、鋳造成形されたアルミニウム製の2つの部材を突き合わせて当該突き合わせ部分を含む所定の幅(接合領域)に攪拌回転子を接触させることで、2つの部材を攪拌接合する。このときに、接合領域が薄肉であると、接合領域に攪拌回転子を接触させた際に突き合わせ部分が開いて隙間ができ、接合領域に内部欠陥が発生し易くなる。そのため、接合領域は厚肉部として構成される必要があるが、上述したように厚肉部には鋳巣が発生しやすい。ここで、アルミケースでは、内部の換気用や内部に収容する部材の挿入用等として接合領域に貫通孔を形成することがある。こうした貫通孔は、例えば、2つの部材に跨って形成される。貫通穴が接合領域の厚肉部に形成された場合、アルミケースにおいて貫通穴の内周面(加工面)に鋳巣が露出することがある。アルミケースでは、貫通穴は内部からの反力を受ける場合があるため、貫通穴の内周面に鋳巣が存在すると当該鋳巣に応力集中が起こり、貫通穴の周囲の部位が破損するおそれがある。 In the friction stir welding method used to manufacture aluminum cases, two cast aluminum members are butted together and a stirrer is brought into contact with a predetermined width (joint area) including the butted portion, thereby stir-joining the two members. If the joint area is thin, the butted portion opens when the stirrer is brought into contact with the joint area, creating a gap, making it easy for internal defects to occur in the joint area. For this reason, the joint area needs to be configured as a thick-walled portion, but as mentioned above, casting holes are likely to occur in the thick-walled portion. Here, in aluminum cases, through holes are sometimes formed in the joint area for internal ventilation or for inserting members to be housed inside. Such through holes are formed, for example, across two members. When a through hole is formed in the thick-walled portion of the joint area, casting holes may be exposed on the inner surface (machined surface) of the through hole in the aluminum case. In aluminum cases, the through hole may receive a reaction force from the inside, so if a casting hole exists on the inner surface of the through hole, stress concentration occurs in the casting hole, and there is a risk of damage to the area around the through hole.

上記実情に鑑み、アルミケースに形成された貫通孔の内周面に露出する鋳巣を抑制できるアルミケース及びアルミケースの製造方法が望まれている。 In view of the above situation, there is a need for an aluminum case and a method for manufacturing the aluminum case that can suppress the formation of blowholes exposed on the inner circumferential surface of the through hole formed in the aluminum case.

本発明に係るアルミケースの特徴構成は、鋳造により成形されたアルミニウム合金部材である、第1部材及び第2部材が摩擦攪拌接合によって接合された接合部を有し、前記接合部を挟んで前記第1部材と前記第2部材との両方に跨る貫通穴が形成されたアルミケースであって、前記貫通穴の開口端は、周方向に沿って、角部分と角丸部分とからなる点にある。 The aluminum case according to the present invention is characterized in that it is an aluminum case having a joint where a first member and a second member, which are aluminum alloy members formed by casting, are joined by friction stir welding, and a through hole is formed that spans both the first member and the second member across the joint, and the open end of the through hole is made up of an angular portion and a rounded portion along the circumferential direction.

本構成によれば、アルミケースが第1部材と第2部材との接合によって構成され、両部材の接合部を挟んで第1部材と第2部材との両方に跨る貫通孔の開口端が、周方向に沿って、角部分と角丸部分とからなる。ここで、角部分とは、貫通穴の周囲の面と貫通穴の内周面とによって形成される直角部分に相当する。こうした角部分は、例えばドリル等による貫通穴の加工によって形成することができる。一方、角丸部分は、貫通穴の開口端の角部分が貫通穴の貫通方向にR状に丸められた部分に相当する。こうした角丸部分は、鋳造により成形された第1部材及び第2部材であれば、鋳造の際に設けられる鋳抜き部分によって形成することができ、ドリル等による貫通穴の加工後であっても残存する場合がある。鋳造時に鋳抜き部分を形成すると、鋳抜き部分の近傍の肉厚は薄肉となり、鋳巣が発生し難い。このため、鋳抜き部分に近接した位置にアルミケースの貫通穴を形成した場合、鋳抜き部分の近傍は鋳巣が発生し難いので、貫通穴の内周面に鋳巣が露出するのを抑制することができる。また、アルミケースの貫通穴の角丸部分は、アルミケースに各種部材を挿入する際のガイド部として機能させることもできる。 According to this configuration, the aluminum case is formed by joining the first member and the second member, and the opening end of the through hole that straddles both the first member and the second member across the joint between the two members is composed of a corner portion and a rounded corner portion along the circumferential direction. Here, the corner portion corresponds to a right angle portion formed by the surface around the through hole and the inner peripheral surface of the through hole. Such a corner portion can be formed by processing the through hole with a drill or the like. On the other hand, the rounded corner portion corresponds to a portion in which the corner portion of the opening end of the through hole is rounded in an R shape in the penetrating direction of the through hole. If the first member and the second member are formed by casting, such a rounded corner portion can be formed by a cast-out portion provided during casting, and may remain even after processing the through hole with a drill or the like. If a cast-out portion is formed during casting, the thickness near the cast-out portion becomes thin, and blowholes are less likely to occur. Therefore, if a through hole is formed in the aluminum case at a position close to the cast-out portion, blowholes are less likely to occur near the cast-out portion, so that it is possible to suppress exposure of blowholes on the inner peripheral surface of the through hole. Additionally, the rounded corners of the through holes in the aluminum case can also function as guides when inserting various components into the aluminum case.

他の特徴構成として、前記角部分は、前記接合部を挟んで前記第1部材及び前記第2部材に跨り、前記摩擦攪拌接合によって接合された接合領域に形成されており、前記角丸部分は、前記接合領域から前記第1部材及び前記第2部材の夫々に連続する非接合領域に形成されている。 As another characteristic configuration, the corner portion is formed in a joining region that spans the first member and the second member across the joint and is joined by the friction stir welding, and the rounded corner portion is formed in a non-joint region that is continuous from the joining region to each of the first member and the second member.

本構成によれば、アルミケースに形成される貫通穴において、ドリル等を用いた穴加工によって形成可能な角部分が、第1部材及び第2部材の接合領域に形成されている。接合領域は摩擦攪拌接合によって第1部材及び第2部材が接合された領域であり、摩擦攪拌接合の際に回転子によって攪拌される領域である。このため、第1部材及び第2部材において接合領域となる部位は剛性を確保する上で厚肉にする必要がある。したがって、第1部材及び第2部材の鋳造時において、摩擦攪拌接合により接合領域となる部位には、鋳抜き部分を形成して薄肉化を図ることができない。その結果、鋳抜き部分でない箇所に形成された貫通穴の開口端は角部分となる。すなわち、角部分は接合領域に形成されることとなる。一方、非接合領域は摩擦攪拌接合の影響を受けない領域であるので、厚肉にする必要はなく、当該領域には鋳抜き部分を設けることが可能である。そして、鋳抜き部分の開口端は角丸に形成することができる。したがって、貫通穴の開口端の角丸部分は非接合領域において鋳抜き部分に形成された角丸部分である。すなわち、角丸部分は非接合領域に形成することができる。このように、貫通穴の開口端において、角部分が接合領域に形成され、角丸部分が非接合領域に形成されることで、アルミケースは、接合部の剛性を確保しつつ、貫通穴の内周面に鋳巣が露出するのを抑制することができる。 According to this configuration, in the through hole formed in the aluminum case, a corner portion that can be formed by hole processing using a drill or the like is formed in the joining region of the first member and the second member. The joining region is the region where the first member and the second member are joined by friction stir welding, and is the region that is stirred by the rotor during friction stir welding. For this reason, the portion that becomes the joining region in the first member and the second member needs to be made thick to ensure rigidity. Therefore, when casting the first member and the second member, it is not possible to form a cast-out portion in the portion that becomes the joining region by friction stir welding to make it thinner. As a result, the opening end of the through hole formed in the portion that is not the cast-out portion becomes a corner portion. In other words, the corner portion is formed in the joining region. On the other hand, since the non-joining region is a region that is not affected by friction stir welding, it is not necessary to make it thick, and it is possible to provide a cast-out portion in that region. And the opening end of the cast-out portion can be formed with round corners. Therefore, the round corner portion of the opening end of the through hole is a round corner portion formed in the cast-out portion in the non-joining region. In other words, the round corner portion can be formed in the non-joining region. In this way, at the open end of the through hole, the corners are formed in the joint area and the rounded corners are formed in the non-joint area, so that the aluminum case can prevent blowholes from being exposed on the inner surface of the through hole while ensuring the rigidity of the joint.

本発明に係るアルミケースの製造方法の特徴構成は、アルミニウム合金部材からなり、鋳抜き部分を有する第1部材及び第2部材を鋳造により形成する鋳造工程と、前記第1部材と前記第2部材とを当接させて、該当接させた当接部分に摩擦攪拌用回転子を作用させて前記第1部材及び前記第2部材を摩擦攪拌接合により接合して接合部を形成する接合工程と、前記接合部を挟んで前記第1部材及び前記第2部材に跨り、且つ、夫々の前記鋳抜き部分の少なくとも一部が含まれる箇所に貫通穴を形成する穴形成工程と、を有し、前記貫通穴は、前記接合部を挟んで前記第1部材及び前記第2部材に跨り、前記摩擦攪拌接合によって接合された領域である接合領域と、前記接合領域から前記第1部材及び前記第2部材の夫々に連続する領域である非接合領域とを有し、前記貫通穴の開口端のうち前記非接合領域に位置する箇所は、前記鋳抜き部分により形成されている点にある。 The manufacturing method of the aluminum case according to the present invention is characterized by the following: a casting process for forming a first member and a second member made of aluminum alloy members and having a cast-out portion by casting; a joining process for abutting the first member and the second member and applying a friction stir rotor to the abutting portion to join the first member and the second member by friction stir welding to form a joint; and a hole forming process for forming a through hole in a location that straddles the first member and the second member across the joint and includes at least a part of each of the cast-out portions, the through hole having a joint region that straddles the first member and the second member across the joint and is joined by the friction stir welding, and a non-joint region that is a region that continues from the joint region to each of the first member and the second member, and the portion of the open end of the through hole that is located in the non-joint region is formed by the cast-out portion.

本構成によれば、アルミニウム合金部材からなる第1部材及び第2部材に対し、鋳造工程、接合工程、及び穴形成工程を行うことで、貫通穴を有するアルミケースを適正に製造することができる。ここで、貫通穴は、第1部材及び第2部材に跨り、接合領域及び非接合領域に形成され、貫通穴の開口端のうち非接合領域に位置する箇所は、鋳抜き部分により形成されている。すなわち、アルミケースに形成される貫通穴は、非接合領域おいて鋳抜き部分の一部を含む領域に形成される。第1部材及び第2部材において鋳抜き部分の近くは厚みが薄くなることで内部に鋳巣が発生し難くなる。したがって、製造されたアルミケースにおいて、貫通穴の内周面に鋳巣が露出するのを抑制することができる。 According to this configuration, an aluminum case having a through hole can be properly manufactured by performing a casting process, a joining process, and a hole forming process on a first member and a second member made of an aluminum alloy member. Here, the through hole is formed in the joining region and the non-jointed region across the first member and the second member, and the portion of the open end of the through hole located in the non-jointed region is formed by the cast-out portion. In other words, the through hole formed in the aluminum case is formed in a region that includes a part of the cast-out portion in the non-jointed region. The first member and the second member are thinner near the cast-out portion, making it difficult for blowholes to occur inside. Therefore, it is possible to suppress the exposure of blowholes on the inner surface of the through hole in the manufactured aluminum case.

他の特徴構成は、前記鋳抜き部分の内周面のうち前記接合部から遠い側の前記内周面の形状が前記貫通穴の内周面の形状と略同じ形状である点にある。 Another characteristic feature is that the shape of the inner circumferential surface of the cast-out portion on the side farther from the joint is substantially the same as the shape of the inner circumferential surface of the through hole.

本構成によれば、鋳抜き部分の内周面のうち接合部から遠い側の内周面の形状が貫通穴の内周面の形状と略同じ形状であるので、貫通穴を鋳抜き部分の内周面に沿わせて形成することができ、穴形成工程を容易に行うことができる。鋳抜き部分はアルミケースにおいて部材の厚みが薄い部分であるので、貫通穴の周囲に鋳抜き部分が多く存在した場合には貫通穴の強度が低下することがある。しかし、本構成であれば、貫通穴を鋳抜き部分の内周面に沿わせて形成することで、第1部材及び第2部材の鋳抜き部分は貫通穴によって大部分を除去することができる。これにより、アルミケースにおいて貫通穴の周囲に残存する鋳抜き部分の領域を小さくすることができる。その結果、製造されたアルミケースにおいて貫通穴の周辺部位の強度低下を抑制することができる。 According to this configuration, the shape of the inner peripheral surface of the cast-out portion farther from the joint is substantially the same as the shape of the inner peripheral surface of the through hole, so the through hole can be formed along the inner peripheral surface of the cast-out portion, and the hole forming process can be easily performed. Since the cast-out portion is a portion of the aluminum case where the thickness of the member is thin, the strength of the through hole may decrease if there are many cast-out portions around the through hole. However, with this configuration, by forming the through hole along the inner peripheral surface of the cast-out portion, the cast-out portions of the first member and the second member can be largely removed by the through hole. This makes it possible to reduce the area of the cast-out portion remaining around the through hole in the aluminum case. As a result, it is possible to suppress the decrease in strength of the surrounding area of the through hole in the manufactured aluminum case.

アルミケースの斜視図及び要部平面図である。2A and 2B are a perspective view and a plan view of a main portion of an aluminum case. 図1のII-II矢視断面図である。2 is a cross-sectional view taken along the line II-II of FIG. 1. 図1のIII-III矢視断面図である。3 is a cross-sectional view taken along the line III-III in FIG. 1 . 第1部材及び第2部材の要部平面図である。FIG. 2 is a plan view of a main portion of a first member and a second member. 図4のV-V矢視断面図である。5 is a cross-sectional view taken along the line VV in FIG. 4. アルミケースの製造途中における第1部材及び第2部材の断面図である。4 is a cross-sectional view of a first member and a second member during the manufacturing process of the aluminum case. FIG. アルミケースの製造途中における第1部材及び第2部材の要部平面図である。1 is a plan view of a main portion of a first member and a second member during the manufacturing process of an aluminum case. FIG. アルミケースの製造途中における第1部材及び第2部材の断面図である。4 is a cross-sectional view of a first member and a second member during the manufacturing process of the aluminum case. FIG. 別形態の第1部材及び第2部材の要部平面図である。FIG. 11 is a plan view of a main portion of a first member and a second member according to another embodiment. 別形態の第1部材及び第2部材の要部平面図である。FIG. 11 is a plan view of a main portion of a first member and a second member according to another embodiment. 別形態の第1部材及び第2部材の断面図である。FIG. 11 is a cross-sectional view of a first member and a second member according to another embodiment.

以下、本発明の実施形態に係るアルミケース及びアルミケースの製造方法を図面に基づいて説明する。 The following describes an aluminum case and a method for manufacturing an aluminum case according to an embodiment of the present invention with reference to the drawings.

図1はアルミケース1の一例を示す。アルミケース1は、鋳造により成形されたアルミニウム合金である、有底角筒状の第1部材11及び有底角筒状の第2部材12とを接合して構成されている。図1に示すように、アルミケース1は、第1部材11及び第2部材12が接合部13において接合されて一体化されている。第1部材11と第2部材12とは、摩擦攪拌接合によって接合されており、第1部材11は周囲より厚さが厚い被加工部A1を有し、第2部材12は周囲より厚さが厚い被加工部A2を有する(図3参照)。摩擦攪拌接合に用いる回転子3(摩擦攪拌用回転子の一例、図6参照)が接触して摩擦攪拌接合された領域である接合領域14は、被加工部A1及び被加工部A2に跨って形成される。第1部材11の被加工部A1は、接合領域14と、接合領域14以外の領域である非接合領域15とを有する。第2部材12の被加工部A2は、接合領域14と、接合領域14以外の領域である非接合領域16とを有する。 1 shows an example of an aluminum case 1. The aluminum case 1 is formed by joining a first member 11 and a second member 12, which are aluminum alloys formed by casting, and are in the shape of a rectangular cylinder with a bottom. As shown in FIG. 1, the aluminum case 1 is formed by joining the first member 11 and the second member 12 at a joint 13 to form an integrated body. The first member 11 and the second member 12 are joined by friction stir welding, and the first member 11 has a processed part A1 that is thicker than the surrounding area, and the second member 12 has a processed part A2 that is thicker than the surrounding area (see FIG. 3). The joint area 14, which is an area friction stir welded by contacting the rotor 3 used for friction stir welding (an example of a rotor for friction stir welding, see FIG. 6), is formed across the processed part A1 and the processed part A2. The processed part A1 of the first member 11 has the joint area 14 and a non-joined area 15, which is an area other than the joint area 14. The processed portion A2 of the second member 12 has a bonding region 14 and a non-bonding region 16, which is the region other than the bonding region 14.

図1~図3に示されるように、アルミケース1には、不図示のドリル等の加工による貫通穴17が形成されている。貫通穴17は、第1部材11と第2部材12とに跨って、且つ、接合領域14から非接合領域15,16に亘って形成されている。貫通穴17の開口端18には、角部分23aと角丸部分21a,22aが形成されている。貫通穴17の実質的な内周面は、ドリル等により加工された加工面23である。加工面23は、開口端18の角部分23a及び角丸部分21a,22aから連続する直線部23bによって構成されている。本実施形態では、貫通穴17の断面は円形状である。貫通穴17の断面は、楕円、長円等の円形状や、矩形等の角形状であってもよい。 As shown in Figs. 1 to 3, the aluminum case 1 has a through hole 17 formed by processing with a drill or the like (not shown). The through hole 17 is formed across the first member 11 and the second member 12, and from the joint region 14 to the non-joint regions 15 and 16. The opening end 18 of the through hole 17 has a corner portion 23a and rounded corner portions 21a and 22a. The actual inner peripheral surface of the through hole 17 is a processed surface 23 processed with a drill or the like. The processed surface 23 is composed of the corner portion 23a of the opening end 18 and the straight portion 23b continuing from the rounded corner portions 21a and 22a. In this embodiment, the cross section of the through hole 17 is circular. The cross section of the through hole 17 may be circular, such as an ellipse or an oval, or angular, such as a rectangle.

貫通穴17は、アルミケース1の側面2に設けられている。貫通穴17の開口端18の角部分23aは、接合部13を挟んで第1部材11及び第2部材12に跨り、摩擦攪拌接合によって接合された接合領域14に2箇所形成されている。貫通穴17の開口端18の角丸部分21a,22aは、接合領域14から第1部材11及び第2部材12の夫々に連続する非接合領域15,16に形成されている。すなわち、貫通穴17の開口端18は、周方向に沿って、2つの角部分23aと角丸部分21a,22aとからなる。 The through hole 17 is provided in the side surface 2 of the aluminum case 1. The corner portions 23a of the opening end 18 of the through hole 17 are formed in two places in the joining region 14 that straddles the first member 11 and the second member 12 across the joining portion 13 and is joined by friction stir welding. The rounded corner portions 21a, 22a of the opening end 18 of the through hole 17 are formed in the non-jointed regions 15, 16 that continue from the joining region 14 to the first member 11 and the second member 12, respectively. In other words, the opening end 18 of the through hole 17 consists of two corner portions 23a and rounded corner portions 21a, 22a along the circumferential direction.

ここで、角部分23aとは、接合領域14における貫通穴17の周囲の被加工部A1,A2の上面4と貫通穴17の内周面(加工面23)とによって形成される直角部分に相当する。こうした角部分23aは、例えば貫通穴17の加工用のドリル等によって形成することができる。一方、角丸部分21a,22aは、非接合領域15,16における貫通穴17の開口端18がR状に丸められた部分に相当する。こうした角丸部分21a,22aは、鋳造により成形されたアルミニウム合金部材である、第1部材11及び第2部材12であれば、鋳造の際に設けられる鋳抜き部分21,22(図3参照)によって形成することができる。ここで、鋳抜き部分21,22とは、第1部材11及び第2部材12の被加工部A1,A2の厚さ方向に形成される凹部のことである。鋳抜き部分21,22を形成することで、その近傍の肉厚を薄肉にすることができる。また、鋳抜き部分21,22の内周面33,34のうち接合部13から遠い側の内周面33b,34b(図4参照)の形状を貫通穴17の内周面の形状と略同じ形状にすることにより、鋳抜き部分21,22に近接した位置にアルミケース1の貫通穴17を形成することができる。鋳抜き部分21,22の近傍は薄肉であるため、鋳巣が発生し難くなり、アルミケース1において貫通穴17の内周面(加工面23)に鋳巣が露出するのを抑制することができる。 Here, the corner portion 23a corresponds to a right angle portion formed by the upper surface 4 of the processed portion A1, A2 around the through hole 17 in the joining region 14 and the inner peripheral surface (machined surface 23) of the through hole 17. Such corner portion 23a can be formed, for example, by a drill for machining the through hole 17. On the other hand, the rounded corner portions 21a, 22a correspond to the portion where the opening end 18 of the through hole 17 in the non-joining region 15, 16 is rounded in an R shape. If the first member 11 and the second member 12 are aluminum alloy members formed by casting, such rounded corner portions 21a, 22a can be formed by the cast-out portions 21, 22 (see FIG. 3) provided during casting. Here, the cast-out portions 21, 22 are recesses formed in the thickness direction of the processed portions A1, A2 of the first member 11 and the second member 12. By forming the cast-out portions 21, 22, the thickness of the vicinity thereof can be made thin. In addition, by making the shape of the inner peripheral surface 33b, 34b (see FIG. 4) of the inner peripheral surface 33, 34 of the cast-out portions 21, 22, which is farther from the joint portion 13, approximately the same shape as the inner peripheral surface of the through hole 17, the through hole 17 of the aluminum case 1 can be formed in a position close to the cast-out portions 21, 22. Since the vicinity of the cast-out portions 21, 22 is thin, it is difficult for blowholes to occur, and it is possible to prevent blowholes from being exposed on the inner peripheral surface (machined surface 23) of the through hole 17 in the aluminum case 1.

図3に示すように、貫通穴17は、アルミケース1に各種部材40を挿入する際や、アルミケース1内の換気等のために用いられる。このとき、角丸部分21a,22aはアルミケース1に各種部材40を挿入する際のガイド部として機能させることができる。 As shown in FIG. 3, the through hole 17 is used when inserting various members 40 into the aluminum case 1 and for ventilation inside the aluminum case 1. In this case, the rounded corners 21a and 22a can function as guides when inserting various members 40 into the aluminum case 1.

また、本実施形態のアルミケース1では、貫通穴17においてドリル等を用いた穴加工形成可能な角部分23aが、第1部材11及び第2部材12の接合領域14に形成されている。接合領域14は摩擦攪拌接合によって第1部材11及び第2部材12が接合された領域であり、摩擦攪拌接合の際に回転子3(図6参照)によって攪拌される領域である。このため、第1部材11及び第2部材12において接合領域14となる部位は剛性を確保する上で厚肉にする必要がある。したがって、第1部材11及び第2部材12の鋳造時において、摩擦攪拌接合により接合領域14となる部位には、鋳抜き部分21,22を形成して薄肉化を図ることができない。その結果、鋳抜き部分21,22でない箇所に形成された貫通穴17の開口端18は角部分23aとなる。すなわち、角部分23aは接合領域14に形成されることとなる。一方、接合領域14から第1部材11及び第2部材12の夫々に連続する非接合領域15,16は、摩擦攪拌接合の影響を受けない領域であるので、厚肉にする必要はなく、当該領域には鋳抜き部分21,22を設けることが可能である。そして、鋳抜き部分21,22の開口端18Aは、角丸状の角丸部分21aA,22aA(図5、図6、図8参照)を形成することができる。したがって、貫通穴17の開口端18の角丸部分21a,22aは、非接合領域15,16において鋳抜き部分21,22に形成された角丸部分21aA,22aAの一部である。すなわち、角丸部分21a,22aは、角丸部分21aA,22aAが後述する穴形成工程においてドリル等によって加工された後の部分である。このように、貫通穴17の開口端18において、角部分23aが接合領域14に形成され、角丸部分21a,22aが非接合領域15,16に形成されることで、アルミケース1は、接合部13の剛性を確保しつつ、貫通穴17の内周面(加工面23)に鋳巣が露出するのを抑制することができる。 In addition, in the aluminum case 1 of this embodiment, the corner portion 23a that can be formed by drilling or the like in the through hole 17 is formed in the joining region 14 of the first member 11 and the second member 12. The joining region 14 is the region where the first member 11 and the second member 12 are joined by friction stir welding, and is the region that is stirred by the rotor 3 (see FIG. 6) during friction stir welding. For this reason, the portion that becomes the joining region 14 in the first member 11 and the second member 12 needs to be thick to ensure rigidity. Therefore, when casting the first member 11 and the second member 12, the portion that becomes the joining region 14 by friction stir welding cannot be thinned by forming the cast-out portions 21, 22. As a result, the opening end 18 of the through hole 17 formed in the portion that is not the cast-out portion 21, 22 becomes the corner portion 23a. In other words, the corner portion 23a is formed in the joining region 14. On the other hand, the non-bonded regions 15, 16 continuing from the bonding region 14 to the first member 11 and the second member 12, respectively, are not affected by the friction stir welding, so there is no need to make them thick, and it is possible to provide the cast-out portions 21, 22 in the regions. The open ends 18A of the cast-out portions 21, 22 can be formed with rounded corners 21aA, 22aA (see Figs. 5, 6, and 8). Therefore, the rounded corners 21a, 22a of the open ends 18 of the through holes 17 are part of the rounded corners 21aA, 22aA formed in the cast-out portions 21, 22 in the non-bonded regions 15, 16. That is, the rounded corners 21a, 22a are the portions after the rounded corners 21aA, 22aA are machined by a drill or the like in the hole forming process described later. In this way, at the opening end 18 of the through hole 17, the corner portion 23a is formed in the joint area 14, and the rounded corner portions 21a, 22a are formed in the non-joint areas 15, 16, so that the aluminum case 1 can prevent the exposure of blowholes on the inner surface (machined surface 23) of the through hole 17 while ensuring the rigidity of the joint 13.

以下、アルミケース1の製造方法について図4から図8を用いて説明する。アルミケース1の製造方法は、鋳造工程、接合工程、及び穴形成工程を有する。 The manufacturing method of the aluminum case 1 will be described below with reference to Figures 4 to 8. The manufacturing method of the aluminum case 1 includes a casting process, a joining process, and a hole forming process.

〔鋳造工程〕
鋳造工程では、アルミニウム合金部材からなり、鋳抜き部分21を有する第1部材11と、鋳抜き部分22を有する第2部材12とを鋳造により成形する。鋳造工程によって、図4及び図5に示すように、第1部材11には被加工部A1に鋳抜き部分21が形成され、第2部材12には被加工部A2に鋳抜き部分22が形成される。鋳抜き部分21、22は、第1部材11及び第2部材12の上面4から厚さ方向に向かう凹部として形成される。鋳抜き部分21、22の開口端18Aには、全周に亘って角丸部分21aA,22aAが夫々形成されている。角丸部分21aA,22aAとは、鋳抜き部分21,22の開口端18Aにおいて、上面4から鋳抜き部分21,22の底部31,32に向けて丸められた部分である。鋳抜き部分21,22の開口端18Aに形成された角丸部分21aA,22aAの一部は、貫通穴17の開口端18の角丸部分21a,22aになる。
[Casting process]
In the casting process, the first member 11, which is made of an aluminum alloy member and has a cast-out portion 21, and the second member 12, which has a cast-out portion 22, are formed by casting. As shown in Figs. 4 and 5, the cast-out portion 21 is formed in the processed portion A1 of the first member 11, and the cast-out portion 22 is formed in the processed portion A2 of the second member 12 by the casting process. The cast-out portions 21, 22 are formed as recesses extending from the upper surfaces 4 of the first member 11 and the second member 12 in the thickness direction. Rounded corners 21aA, 22aA are formed around the entire circumference of the opening ends 18A of the cast-out portions 21, 22, respectively. The rounded corners 21aA, 22aA are portions that are rounded from the upper surface 4 toward the bottoms 31, 32 of the cast-out portions 21, 22 at the opening ends 18A of the cast-out portions 21, 22. A part of the rounded corners 21 aA, 22 aA formed at the opening end 18 A of the cast-out portions 21, 22 becomes the rounded corners 21 a, 22 a of the opening end 18 of the through hole 17.

鋳抜き部分21,22は、第1部材11及び第2部材12を当接させた当接部分Bに対して対称な形状であり、弓形部分21b,22bと、弓形部分21b,22bの両側に形成される延長部分21c,22cと、を有する。延長部分21c,22cは、弓形部分21b,22bから円弧部分のみが延長されて形成されている。第1部材11の弓形部分21b及び第2部材12の弓形部分22bは、当接部分Bから均等に離間しており、両者の間の距離W3は接合領域14の幅W1よりも大きい。一方、延長部分21cと延長部分22cとの間の距離W2は、接合領域14の幅W1とほぼ同じに設定されている。すなわち、鋳抜き部分21と鋳抜き部分22とは、両者の間の距離W2が接合領域14の幅W1とほぼ同じになるように延長部分21cが設けられている。 The cast-out portions 21 and 22 are symmetrical with respect to the abutment portion B where the first member 11 and the second member 12 are abutted, and have the arched portions 21b and 22b and the extension portions 21c and 22c formed on both sides of the arched portions 21b and 22b. The extension portions 21c and 22c are formed by extending only the arc portions from the arched portions 21b and 22b. The arched portion 21b of the first member 11 and the arched portion 22b of the second member 12 are evenly spaced from the abutment portion B, and the distance W3 between them is greater than the width W1 of the joining area 14. On the other hand, the distance W2 between the extension portions 21c and 22c is set to be approximately the same as the width W1 of the joining area 14. In other words, the cast-out portions 21 and 22 are provided with the extension portions 21c so that the distance W2 between them is approximately the same as the width W1 of the joining area 14.

図4及び図5に示すように、鋳抜き部分21,22は、当接部分B(接合後の接合部13)に沿って設けられており、その内周面33,34には、当接部分B(摩擦攪拌接合後の接合部13)に近い側の内周面33a,34aと、当接部分B(接合後の接合部13)に遠い側の内周面33b,34bと、が存在する。ここで、内周面33b,34bは、後の穴形成工程において形成される貫通穴17(二点鎖線)の内周面の形状と略同じ形状(貫通穴17の半径と略同じ半径の弧状)に形成されている。 As shown in Figures 4 and 5, the cast-out portions 21, 22 are provided along the abutment portion B (joint 13 after joining), and the inner circumferential surfaces 33, 34 include inner circumferential surfaces 33a, 34a on the side closer to the abutment portion B (joint 13 after friction stir welding) and inner circumferential surfaces 33b, 34b on the side farther from the abutment portion B (joint 13 after joining). Here, the inner circumferential surfaces 33b, 34b are formed in approximately the same shape (an arc shape with approximately the same radius as the radius of the through hole 17) as the shape of the inner circumferential surface of the through hole 17 (two-dot chain line) formed in the subsequent hole forming process.

貫通穴17の内周面(加工面23)近傍は、内周面から鋳巣が露出すると、当該鋳巣に応力集中が起こり、貫通穴17の周囲の部位が破損するおそれがあり、薄肉にすることが好ましいため、鋳抜き部分21,22を形成している。しかし、当接部分Bの近傍が薄肉であれば、当接部分Bに回転子3を接触させた際に当接部分Bが開いて隙間ができ、接合部13に内部欠陥が発生するため、厚肉にすることが好ましい。この相反する課題を解決するために、鋳抜き部分21,22は、弓形部分21b,22bと延長部分21c,22cとから構成されている。すなわち、内周面33b,34bは貫通穴17の内周面の近傍であるため、薄肉にすべく延長部分21c,22cを設けて当接部分Bの近傍である距離W2まで薄肉部分を形成している。一方、内周面33a,34aは、貫通穴17の加工により除去される部分であるため、その近傍に鋳巣があったとしても問題がない。そこで、内周面33a,34a間の距離をW3にして、図4に示す平面視で、距離W2よりも厚肉にしている。これにより、後述する摩擦攪拌接合による接合工程においても、当接部分Bが開いて隙間ができることを防止することができる。 In the vicinity of the inner circumferential surface (machined surface 23) of the through hole 17, if a blow hole is exposed from the inner circumferential surface, stress concentration occurs in the blow hole, which may damage the area around the through hole 17, so it is preferable to make the wall thin, and therefore the cast-out portions 21 and 22 are formed. However, if the wall is thin near the abutment portion B, when the rotor 3 is brought into contact with the abutment portion B, the abutment portion B opens, creating a gap, and an internal defect occurs in the joint portion 13, so it is preferable to make the wall thick. In order to solve this conflicting problem, the cast-out portions 21 and 22 are composed of the arched portions 21b and 22b and the extended portions 21c and 22c. That is, since the inner circumferential surfaces 33b and 34b are near the inner circumferential surface of the through hole 17, the extended portions 21c and 22c are provided to make the wall thin, forming a thin wall portion up to the distance W2 near the abutment portion B. On the other hand, the inner circumferential surfaces 33a and 34a are removed by machining the through hole 17, so there is no problem even if there is a blow hole in the vicinity. Therefore, the distance between the inner circumferential surfaces 33a and 34a is set to W3, which is thicker than the distance W2 in the plan view shown in Figure 4. This makes it possible to prevent the abutting portion B from opening and creating a gap even in the joining process by friction stir welding described below.

〔接合工程〕
次に、接合工程において、第1部材11及び第2部材12を接合する。接合工程では、摩擦攪拌接合(Friction Stir Welding)を利用する。摩擦攪拌接合は、被加工物(第1部材11及び第2部材12)よりも硬い材質のプローブ3aを含む回転子3を回転させながら被加工物に摺接させることで、被加工物の突き合わせ部分(当接部分B)を接合する。
[Joining process]
Next, in the joining process, the first member 11 and the second member 12 are joined. In the joining process, friction stir welding is used. In the friction stir welding, a rotor 3 including a probe 3a made of a material harder than the workpieces (the first member 11 and the second member 12) is rotated and brought into sliding contact with the workpieces, thereby joining the butted portions (abutment portion B) of the workpieces.

図6に示すように、突き合わされた第1部材11及び第2部材12の当接部分Bに、回転状態の回転子3の軸心に突設されたプローブ3aを押し付け、この押付け状態のまま回転子3を当接部分Bの延長方向(図4における長手方向)に沿って移動させる。これにより、プローブ3aが当接部分Bに埋入し、この埋入状態のまま当接部分Bに沿って進行してゆく。そして、プローブ3aが通過した部分は第1部材11及び第2部材12の素材であるアルミニウム合金が攪拌混練されて完全に一体化した状態で硬化するため、該プローブ3aが当接部分Bの他端側より離脱した段階で第1部材11及び第2部材12は接合した一体物となる。 As shown in FIG. 6, the probe 3a protruding from the axis of the rotating rotor 3 is pressed against the abutment portion B of the butted first member 11 and second member 12, and the rotor 3 is moved in this pressed state along the extension direction of the abutment portion B (the longitudinal direction in FIG. 4). As a result, the probe 3a is embedded in the abutment portion B and proceeds along the abutment portion B while remaining embedded. The aluminum alloy, which is the material of the first member 11 and the second member 12, is stirred and kneaded in the portion through which the probe 3a passes, and hardens in a completely integrated state. Therefore, when the probe 3a is released from the other end side of the abutment portion B, the first member 11 and the second member 12 are joined together to form an integrated body.

摩擦攪拌接合では、第1部材11及び第2部材12の素材であるアルミニウム合金は、接合領域14のうち、プローブ3aの進行方向前側において摩擦熱によって可塑化状態となり、攪拌混練されながらプローブ3aの進行方向後側へ漸次移行し、プローブ3aの進行方向後側では摩擦熱を失って急速に冷却固化する。 In friction stir welding, the aluminum alloy, which is the material of the first member 11 and the second member 12, becomes plasticized by frictional heat in the joint area 14 at the front side in the direction of travel of the probe 3a, and while being stirred and kneaded, it gradually moves to the rear side in the direction of travel of the probe 3a, where it loses the frictional heat and rapidly cools and solidifies.

当接部分Bにおいては、鋳抜き部分21,22のうち延長部分21c,22cが形成された箇所だけが図4に示す平面視で距離W2となり薄肉になっているものの、その部分は当接部分Bの全体に対して極僅かであり、他の箇所は厚肉であるため、回転子3が押し付けられても、当接部分Bが開いて隙間ができるのを防止することができる。 At the abutment portion B, only the areas where the extensions 21c, 22c of the cast-out portions 21, 22 are formed are thin-walled by a distance W2 in the plan view shown in Figure 4, but this is an extremely small area compared to the entire abutment portion B, and other areas are thick-walled, so even if the rotor 3 is pressed against it, the abutment portion B can be prevented from opening and creating a gap.

〔穴形成工程〕
次に、穴形成工程において、接合部13を挟んで第1部材11及び第2部材12に跨り、且つ、夫々の鋳抜き部分21,22の少なくとも一部が含まれる箇所に貫通穴17を形成する。具体的には、図7及び図8に示されるように、接合領域14に接合跡14aが形成されて接合された第1部材11及び第2部材12に対し、二点鎖線で示される貫通穴17(図8参照)を形成する。貫通穴17はドリル等の加工により形成される。図8に示すように、貫通穴17(二点鎖線)は、鋳抜き部分21,22において開口端18Aに角丸部分21aA,22aAを一部残存させて形成される。図8では、貫通穴17の半径は、内周面33b,34bの半径よりもやや大きいが、内周面33b,34bの半径が貫通穴17の半径と同じであってもよい。
[Hole forming process]
Next, in the hole forming process, a through hole 17 is formed at a location that straddles the first member 11 and the second member 12 across the joint 13 and includes at least a part of each of the cast-out portions 21, 22. Specifically, as shown in Figs. 7 and 8, a through hole 17 (see Fig. 8) indicated by a two-dot chain line is formed in the first member 11 and the second member 12 that are joined with a joint trace 14a formed in the joint region 14. The through hole 17 is formed by processing such as a drill. As shown in Fig. 8, the through hole 17 (two-dot chain line) is formed by leaving a part of the rounded corners 21aA, 22aA at the opening end 18A in the cast-out portions 21, 22. In Fig. 8, the radius of the through hole 17 is slightly larger than the radius of the inner peripheral surfaces 33b, 34b, but the radius of the inner peripheral surfaces 33b, 34b may be the same as the radius of the through hole 17.

上述の通り、アルミニウム合金部材からなる第1部材11及び第2部材12に対し、鋳造工程、接合工程、及び穴形成工程を行うことで、貫通穴17を有するアルミケース1(図1参照)を適正に製造することができる。ここで、貫通穴17は、第1部材11及び第2部材12に跨り、接合領域14及び非接合領域15,16に形成され、貫通穴17の開口端18のうち非接合領域15,16に位置する箇所は、鋳抜き部分21,22により形成されている。すなわち、アルミケース1に形成される貫通穴17は、非接合領域15,16おいて鋳抜き部分21,22の一部を含む領域に形成される。第1部材11及び第2部材12において鋳抜き部分21,22の近くは厚みが薄くなることで内部に鋳巣が発生し難くなる。したがって、貫通穴17の内周面(加工面23)において鋳巣が露出するのを抑制することができる。 As described above, the aluminum case 1 (see FIG. 1) having the through hole 17 can be properly manufactured by performing the casting process, the joining process, and the hole forming process on the first member 11 and the second member 12 made of aluminum alloy members. Here, the through hole 17 is formed across the first member 11 and the second member 12 in the joining region 14 and the non-jointed regions 15, 16, and the portion of the opening end 18 of the through hole 17 located in the non-jointed regions 15, 16 is formed by the cast-out portions 21, 22. That is, the through hole 17 formed in the aluminum case 1 is formed in the region including a part of the cast-out portions 21, 22 in the non-jointed regions 15, 16. The first member 11 and the second member 12 are thin near the cast-out portions 21, 22, making it difficult for blowholes to occur inside. Therefore, it is possible to suppress the exposure of blowholes on the inner peripheral surface (machined surface 23) of the through hole 17.

さらに、本実施形態では、鋳造工程によって、鋳抜き部分21,22の内周面33b,34bは、穴形成工程において形成される貫通穴17の内周面の形状と略同じ形状(貫通穴17の半径と略同じ半径の弧状)に形成されている。したがって、穴形成工程では、貫通穴17を鋳抜き部分21,22の内周面33b,34bに沿わせて形成することができ、貫通穴17を形成することができる。鋳抜き部分21,22はアルミケース1において部材の厚みが薄い部分となるため、貫通穴17の周囲に鋳抜き部分21,22が多く存在した場合にはアルミケース1において貫通穴17の周辺部位の強度が低下することがある。しかし、本構成であれば、貫通穴17を鋳抜き部分21,22の内周面33b,34bに沿わせて形成することで、第1部材11及び第2部材12の鋳抜き部分21,22は、貫通穴17によってアルミケース1から大部分を除去することができる。これにより、アルミケース1において貫通穴17の周囲に残存する鋳抜き部分21,22の領域を小さくすることができる。その結果、製造後のアルミケース1において貫通穴17の周辺部位の強度低下を抑制することができる。 Furthermore, in this embodiment, the inner circumferential surfaces 33b, 34b of the cast-out portions 21, 22 are formed in a shape (arc-shaped with a radius approximately the same as that of the through hole 17) that is substantially the same as the shape of the inner circumferential surface of the through hole 17 formed in the hole forming process. Therefore, in the hole forming process, the through hole 17 can be formed along the inner circumferential surfaces 33b, 34b of the cast-out portions 21, 22, and the through hole 17 can be formed. Since the cast-out portions 21, 22 are the parts of the aluminum case 1 where the thickness of the member is thin, if there are many cast-out portions 21, 22 around the through hole 17, the strength of the parts around the through hole 17 in the aluminum case 1 may decrease. However, with this configuration, by forming the through hole 17 along the inner circumferential surfaces 33b, 34b of the cast-out portions 21, 22, the cast-out portions 21, 22 of the first member 11 and the second member 12 can be largely removed from the aluminum case 1 by the through hole 17. This makes it possible to reduce the area of the cast-out portions 21, 22 remaining around the through hole 17 in the aluminum case 1. As a result, it is possible to suppress a decrease in strength of the area around the through hole 17 in the aluminum case 1 after manufacturing.

〔別実施形態〕
(1)上記の実施形態では、第1部材11及び第2部材12に形成される鋳抜き部分21,22が弓形部分21bと延長部分21cとによって構成される例を示した。鋳抜き部分21,22は、図9に示すように、夫々が弓形状であってもよい。図9に示す例では、鋳抜き部分21と鋳抜き部分22との間の距離W2が、当接部分Bに沿う方向において一定であり、接合領域14の幅W1に等しい。鋳抜き部分21,22は、図10に示すように、夫々が円弧形状であってもよい。図10に示す例では、第1部材11の円弧状の鋳抜き部分21の両端と、鋳抜き部分21に向き合う第2部材12の鋳抜き部分22の両端との距離W2が、接合領域14の幅W1に等しい。図9及び図10に示される鋳抜き部分21,22においても、鋳抜き部分21,22の内周面33,34のうち接合部13から遠い側の内周面33b,34bの形状が貫通穴17の内周面の形状と略同じ形状である。図示しないが、鋳抜き部分21,22は、接合部13に近い側の内周面33a,34aが、図10に示される円弧部分の両端側に加えて中央部分が接合部13に近接するように、内周面33a,34aの中央部分が接合部13に向く凹部によって構成されていてもよい。
[Another embodiment]
(1) In the above embodiment, the cut-out portions 21, 22 formed in the first member 11 and the second member 12 are configured by the arch-shaped portion 21b and the extension portion 21c. As shown in FIG. 9, the cut-out portions 21, 22 may each be arch-shaped. In the example shown in FIG. 9, the distance W2 between the cut-out portion 21 and the cut-out portion 22 is constant in the direction along the abutting portion B and is equal to the width W1 of the joining region 14. As shown in FIG. 10, the cut-out portions 21, 22 may each be arc-shaped. In the example shown in FIG. 10, the distance W2 between both ends of the arc-shaped cut-out portion 21 of the first member 11 and both ends of the cut-out portion 22 of the second member 12 facing the cut-out portion 21 is equal to the width W1 of the joining region 14. 9 and 10 , the shape of the inner circumferential surfaces 33b, 34b of the inner circumferential surfaces 33, 34 of the cut-out portions 21, 22 on the side farther from the joint 13 is substantially the same as the shape of the inner circumferential surface of the through hole 17. Although not shown, the inner circumferential surfaces 33a, 34a of the cut-out portions 21, 22 on the side closer to the joint 13 may be configured with a recess in the central portion of the inner circumferential surfaces 33a, 34a facing the joint 13 so that the central portion is close to the joint 13 in addition to both ends of the arc portion shown in FIG.

(2)上記の実施形態では、図5に示すように、鋳抜き部分21,22は、アルミケース1(第1部材11及び第2部材12)の表面側(側面2の側)のみに形成される例を示した。しかし、図11に示すように、鋳抜き部分21,22は、第1部材11及び第2部材12の両面に設けてもよい。また、図示しないが、鋳抜き部分21,22は、第1部材11及び第2部材12の裏面側(側面2の反対側)のみに形成してもよい。 (2) In the above embodiment, as shown in FIG. 5, an example was shown in which the cut-out portions 21, 22 are formed only on the front side (side surface 2 side) of the aluminum case 1 (first member 11 and second member 12). However, as shown in FIG. 11, the cut-out portions 21, 22 may be provided on both sides of the first member 11 and second member 12. In addition, although not shown, the cut-out portions 21, 22 may be formed only on the back side (opposite side surface 2) of the first member 11 and second member 12.

本発明は、アルミケース及びアルミケースの製造方法において広く利用することできる。 The present invention can be widely used in aluminum cases and methods for manufacturing aluminum cases.

1 :アルミケース
2 :側面
11 :第1部材
12 :第2部材
13 :接合部
14 :接合領域
15,16:非接合領域
17 :貫通穴
18 :開口端
21,22 :鋳抜き部分
21a,22a :角丸部分
23 :加工面(内周面)
23a :角部分
23b :直線部
33,34 :内周面
A1,A2:被加工部
B :当接部分
W1 :接合領域の幅
W2 :2つの鋳抜き部分の間の距離
1: Aluminum case 2: Side surface 11: First member 12: Second member 13: Joint portion 14: Joint region 15, 16: Non-joint region 17: Through hole 18: Opening end 21, 22: Cast-out portion 21a, 22a: Rounded corner portion 23: Machined surface (inner peripheral surface)
23a: Corner portion 23b: Straight portion 33, 34: Inner peripheral surface A1, A2: Processing portion B: Contact portion W1: Width of joining area W2: Distance between two cast-out portions

Claims (3)

鋳造により成形されたアルミニウム合金部材である、第1部材及び第2部材が摩擦攪拌接合によって接合された接合部を有し、前記接合部を挟んで前記第1部材と前記第2部材との両方に跨る貫通穴が形成されたアルミケースであって、
前記貫通穴の開口端は、周方向に沿って、角部分と角丸部分とからなるアルミケース。
An aluminum case having a joint formed by friction stir welding of a first member and a second member, the first member and the second member being aluminum alloy members formed by casting, and a through hole formed in the first member and the second member across the joint,
The aluminum case has an opening end of the through hole that has a corner portion and a rounded corner portion along the circumferential direction.
前記角部分は、前記接合部を挟んで前記第1部材及び前記第2部材に跨り、前記摩擦攪拌接合によって接合された接合領域に形成されており、
前記角丸部分は、前記接合領域から前記第1部材及び前記第2部材の夫々に連続する非接合領域に形成されている請求項1に記載のアルミケース。
The corner portion is formed in a joining region that spans the first member and the second member across the joint and is joined by the friction stir welding,
The aluminum case according to claim 1 , wherein the rounded corners are formed in non-bonded regions that are continuous from the bonded region to each of the first member and the second member.
アルミニウム合金部材からなり、鋳抜き部分を有する第1部材及び第2部材を鋳造により形成する鋳造工程と、
前記第1部材と前記第2部材とを当接させて、該当接させた当接部分に摩擦攪拌用回転子を作用させて前記第1部材及び前記第2部材を摩擦攪拌接合により接合して接合部を形成する接合工程と、
前記接合部を挟んで前記第1部材及び前記第2部材に跨り、且つ、夫々の前記鋳抜き部分の少なくとも一部が含まれる箇所に貫通穴を形成する穴形成工程と、を有し、
前記貫通穴は、前記接合部を挟んで前記第1部材及び前記第2部材に跨り、前記摩擦攪拌接合によって接合された領域である接合領域と、前記接合領域から前記第1部材及び前記第2部材の夫々に連続する領域である非接合領域とを有し、
前記貫通穴の開口端のうち前記非接合領域に位置する箇所は、前記鋳抜き部分により形成されているアルミケースの製造方法。
a casting step of forming a first member and a second member, each of which is made of an aluminum alloy member and has a cast-out portion, by casting;
a joining process in which the first member and the second member are brought into contact with each other and a friction stir rotor is applied to the contacting portion to join the first member and the second member by friction stir welding to form a welded portion;
a hole forming step of forming a through hole at a location that straddles the first member and the second member across the joint portion and includes at least a part of each of the cast-out portions,
The through hole has a joint region that spans the first member and the second member across the joint and is joined by the friction stir welding, and a non-joint region that is a region continuous from the joint region to each of the first member and the second member,
A manufacturing method for an aluminum case, wherein the portion of the open end of the through hole located in the non-jointed region is formed by the cast-out portion.
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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2009255874A (en) 2008-04-21 2009-11-05 Nippon Light Metal Co Ltd Method of manufacturing bracket for front fork, method of manufacturing structure with lid, bracket for front fork and structure with lid
JP2012149669A (en) 2011-01-17 2012-08-09 Nidec-Shimpo Corp Transmission case
JP2013111581A (en) 2011-11-24 2013-06-10 Mitsubishi Heavy Ind Ltd Joined body, vehicle constituted of the joined body, and method for manufacturing the joined body
JP2016509178A (en) 2013-02-22 2016-03-24 マグナ パワートレイン ゲーエムベーハー ウント コ カーゲー Gear box housing and manufacturing method of gear box housing

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2009255874A (en) 2008-04-21 2009-11-05 Nippon Light Metal Co Ltd Method of manufacturing bracket for front fork, method of manufacturing structure with lid, bracket for front fork and structure with lid
JP2012149669A (en) 2011-01-17 2012-08-09 Nidec-Shimpo Corp Transmission case
JP2013111581A (en) 2011-11-24 2013-06-10 Mitsubishi Heavy Ind Ltd Joined body, vehicle constituted of the joined body, and method for manufacturing the joined body
JP2016509178A (en) 2013-02-22 2016-03-24 マグナ パワートレイン ゲーエムベーハー ウント コ カーゲー Gear box housing and manufacturing method of gear box housing

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