JPH10244343A - Manufacture of hollow material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method for a hollow material which easily further charges damping material without need of use of a large diameter extending die. SOLUTION: This method is the one for manufacturing the hollow material continuously formed in the longitudinal direction of two pieces of flat-state outer plate parts parallel separately arranged and plural partition wall parts partitioning a space between both outer plate parts. Firstly, the hollow material body 1 formed from the plate-like part 2 for forming the one side of the outer plate having a bending part A in at least a part of the width direction, and an opening part 6, at which the plate-like part 3 for forming the other side of outer plate having rib parts 4 for forming the partition wall parts does not exist in at least the faced position to the bending part A, is manufactured by extruding formation. Successively, the hollow material body 1 is extended as the flat-state in the bending part A. Then, after charging the damping material from the opening part 6, a cover member 10 is fitted to the opening part 6 in the fixed state by friction-stirring joining method, etc.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a hollow material used as a floor material, a wall material, a ceiling material, a structural member of a building structure, or the like of vehicles such as railways and buses and ships, for example.

[0002] In this specification, the term "aluminum" is used to include its alloy.

[0003]

2. Description of the Related Art As this kind of hollow material, for example, a large hollow material (31) as shown in FIG. 12 is sometimes used.

A hollow member (31) shown in FIG. 1 is made of a metal such as aluminum, and has two wide and long flat plate-like outer plate portions (32) (32) ( 3
3) as a reinforcing rib which extends in the longitudinal direction by communicating the outer plate portions (32) and (33) and partitions the space between the outer plate portions (32) and (33) in parallel in the width direction. And a plurality of partition portions (34) (34). (35)
(35)... Are the hollow portions.

[0005]

In general, a hollow material can be easily manufactured by ordinary extrusion. However, since the hollow material (31) shown in FIG. Large diameters had to be used, and there was a limit in designing and manufacturing such dies.

Further, each hollow portion (35) of the hollow material (31)
... may be loaded with a damping material (not shown) along the length direction. In this case, the damping material is a hollow material (31).
The loading operation was rather troublesome because the loading operation had to be performed from the end face in the longitudinal direction.

[0007] However, in order to obtain a wide flat plate-like material which is not a hollow material, a material to be developed and extruded, which has a bent portion in at least a portion in the width direction, is extruded. 2. Description of the Related Art It has been conventionally performed to obtain an intended plate-like material by developing an unfolded material flat at a bent portion. This method has the advantage that the required die diameter can be reduced.

However, this method is mainly used for producing a flat plate-like material, and cannot be applied to the production of a wide hollow material (31) as shown in FIG. Was. This is because, when the flat plate is unfolded, a tensile force acts on one of the outer plates (32) and (33) and a compressive force acts on the other in the bent portion, so that flattening cannot be performed. is there.

SUMMARY OF THE INVENTION The present invention has been made to solve such a problem, and does not require the use of a large-diameter extrusion die in the production of a hollow material, and furthermore, a hollow material in which a vibration damping material can be easily loaded. It is intended to provide a method for producing the same.

[0010]

In order to achieve the above-mentioned object, a first aspect of the present invention is to dispose two parallelly spaced apart two-pieces.
A method of manufacturing a hollow material for manufacturing a hollow material in which a plurality of flat outer plate portions and a plurality of partition portions partitioning a space between both outer plate portions are formed continuously in a length direction. A plate portion for forming the one outer plate portion having a bent portion in at least a part of the width direction, and a rib portion for forming the partition wall portion, and at least a portion opposed to the bent portion, A hollow material body in which an opening without the plate portion for the other outer plate portion is formed is manufactured by extrusion molding, and the hollow material body is flattened and processed at the bent portion. A cover member is fixedly mounted on the opening.

According to this structure, since the hollow material body as described above is manufactured by extrusion molding, a die having a large die diameter is used when manufacturing a hollow material as in the case of directly extruding a wide hollow material. Eliminates the need. Also, when the vibration damping material is loaded in the hollow portion, the vibration damping material is loaded into the hollow portion by mounting the cover member after loading the vibration damping material from the opening of the plate portion. Therefore, the operation of loading the vibration damping material becomes easy.

According to a second aspect, in the method for manufacturing a hollow member according to the first aspect, each side edge of the opening of the plate-shaped portion is
The cover member has a concave portion for fitting the cover member which is depressed corresponding to the thickness of each side edge portion of the cover member.

According to this configuration, when the cover member is mounted on the opening, the outer surface of the outer plate portion and the outer surface of the cover member are flush, and the outer surface of the hollow member is flat.

According to a third aspect of the present invention, in the method for manufacturing a hollow member according to the first or second aspect, each of the side edges on the inner surface side of the cover member has a projection that abuts against a side surface of the rib portion. Adopted.

According to this configuration, when the cover member is attached to the opening, the protrusion comes into contact with the side surface of the rib, so that lateral displacement in the width direction is prevented.

According to a fourth aspect of the present invention, in the method for manufacturing a hollow member according to any one of the first to third aspects, a configuration is adopted in which the cover member is joined and fixed by friction stir welding.

According to this configuration, when the cover member is joined and fixed, the strength of the weld heat affected zone such as MIG welding or TIG welding is reduced and thermal distortion is generated, and further, the type of metal constituting the hollow member is restricted. Inconvenience such as receiving
The cover member is securely fixed.

[0018]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, the present invention will be described based on illustrated embodiments. In this embodiment, for convenience of explanation, the upper side of the paper in FIG.

FIGS. 1 to 5 illustrate the first embodiment of the present invention, and manufacture a wide hollow member (31) as shown in FIG. As described above, the hollow member (31) has two upper and lower flat outer plate portions (32) and (33) which are arranged in parallel and spaced apart from each other.
And a plurality of (eight in the figure) partition walls (34) (34), which partition the gap between these outer plates (32) (33), are formed continuously in the longitudinal direction. It is made of. (35) (35)... Are the hollow portions,
There are seven in total.

In this embodiment, the wide hollow material body (11) and the flat cover member (2) shown in FIG.
0) to manufacture a hollow member (31) as shown in FIG. The hollow material body (1) and the cover member (10) are both made of aluminum. The hollow member main body (1) shown in the figure is formed into a flat shape by performing a development process as described later, and the cover member (10) is made of a normal extruded member.

Hereinafter, a method of manufacturing such a hollow member (31) will be described along the manufacturing steps.

First, a hollow material body (1) having a substantially inverted V-shaped cross section as shown in FIG. 1 is manufactured by extrusion molding. That is, the upper plate-shaped portion (2) for forming the upper outer plate portion (32) having the bent portion (A) at the middle portion in the width direction by extrusion molding, and the rib portion () for forming the partition wall portion (34). 4) ...
And a hollow member body having an opening (6) in which a lower plate-shaped portion (3) for forming a lower outer plate portion (33) is not formed in a portion facing the bent portion (A). (1) is manufactured.
One hollow portion of the hollow material body (1) has disappeared due to the presence of the opening (6).

The hollow material body (1) is formed by using an extruder (not shown) equipped with a die (not shown) having a molding gap corresponding to a predetermined sectional shape according to a conventional method, and using an aluminum billet. And extrusion-molded. As the dice, a combination dice such as a porthole dice is preferably used.

Then, the hollow material main body (1) is flattened at the bent portion (A).

This unfolding process can be easily performed by using a known unfolding device (not shown).

Next, as shown in FIGS. 2 and 3, a cover member (10) is attached to the opening (6) of the lower plate-shaped portion (3). Here, when it is necessary to load a damping material (not shown), the damping material is loaded from the opening (6), and then the cover member (10) is attached.

The cover member (10) is formed to have a width slightly larger than the width of the opening (6) of the lower plate-shaped portion (3) and has a length equal to the length of the opening (6). 4, and each side edge can be overlapped with the opening (6) each side edge of the lower plate-shaped portion (3) as shown in FIG. At the same time, the opening (6) can be covered so as to cover the opening (6) along the length direction.

Then, each side edge of the cover member (10) is superimposed on each side edge of the opening (6) of the lower plate-like portion (3), and as shown in FIGS. (1
9) Each side edge is integrally joined and fixed at the overlapping portion (15) by friction stir welding. As a result, the cover member (10) is fixedly attached to the opening (6) of the lower plate-shaped portion (3).

The friction stir welding will be described. 4 and 5, reference numeral (20) denotes a friction stir welding apparatus, in which a small-diameter pin-shaped probe (22) protrudes and is integrally provided on an end axis of a large-diameter cylindrical rotor (21). By rotating the rotor (21) at a high speed, the probe (22) can also be rotated at a high speed. The probe (22) and the rotor (21) are made of a heat-resistant material that is harder than the hollow material body (1) and the cover member (10) and that can withstand frictional heat generated during joining.

First, the rotor (21) of the joining device (20)
To bring the probe (22), which rotates together with the probe, into contact with the side edge of the cover member (10). Then, the contact portion is softened and plasticized by the frictional heat generated by the contact, and the probe (22) is further pressed to insert the tip of the probe (22) to the lower plate-shaped portion (3). With the probe (22) inserted, the flat shoulder (21a) at the tip of the rotor (21) is brought into contact with the outer surface of the side edge of the cover member (10) (FIG. 5). The contact of the shoulder (21a) can prevent the material of the softened portion at the time of joining start or in the middle of joining from being scattered, thereby realizing a uniform joining state, and at the same time, with the outer surface of the side edge of the cover member (10). The frictional heat generated by sliding with the shoulder (21a) is generated to promote the softening of the contact portion with the probe (22) or the vicinity thereof.

After inserting the probe (22), the rotor (21) is moved along the side edge of the opening (6) of the lower plate portion (3). Due to the rotation of the probe (22) and the rotor (21), the side edge of the cover member (10) and the opening (6) side edge of the lower plate-shaped portion (3) around the contact portion with the probe (22). Parts are softened by frictional heat and are agitated with each other. Then, by the movement of the probe (22),
The probe (2) so that the softening and stirring portion receives the traveling pressure of the probe (22) and fills the passage groove of the probe (22).
After plastically flowing in a mode of wrapping backward in the traveling direction of 2), frictional heat is rapidly lost and solidified by rapid cooling.

In this way, the softening, stirring and cooling and solidification of the joint are sequentially repeated with the movement of the probe (22), and the cover member (10) is attached to the lower plate-like portion (3) in the overlapping portion (15). Are integrally joined and fixed, and an intended hollow material (31) having seven hollow portions (5) in the width direction is obtained.

In the first embodiment, the hollow material main body (1) has a lower plate-shaped portion (3) with one opening (6) formed therein, as shown in FIG. Alternatively, the lower plate-shaped portion (3) having three openings (6), (6), and (6) may be used. By increasing the number of openings (6) in this manner, a large number of vibration damping materials can be easily loaded. FIG. 6 corresponds to FIG. 1 used in the description of the first embodiment, and in FIG. 6, the same components as those shown in FIGS. 1 to 5 are denoted by the same reference numerals. Have been.

The lower plate-shaped portion (3) of the hollow material main body (1) has three openings (6), (6) (6) ( 6) are formed, and the presence of these openings (6), (6), (6)
Three of the hollow portions (5) ... have disappeared. And an upper plate-shaped part (2) for forming an upper outer plate part (32)
Is bent at an intermediate portion in the width direction to exhibit a substantially inverted V-shaped cross section. The hollow material body (1) having such a cross-sectional shape is manufactured by extrusion molding, and thereafter, flattening is performed at the bent portion (A).

Next, each opening (6) of the lower plate-like portion (3)
(6) By attaching three cover members (not shown) in a fixed state to the openings (6) to cover the openings (6), respectively, the seven hollow portions (5) in the width direction are provided. The desired hollow material (31) having ... is produced. When the damping material is loaded, the damping material is loaded from each of the three openings (6), (6), (6), and then the cover member is moved to the openings (6), (6), (6), (6). 6) Attach each in a fixed state.

FIGS. 7 and 8 show the shape of each side edge of the opening (6) of the lower plate-shaped portion (3) in these embodiments.
It shows two modified examples in which the shape of each side edge of the cover member (10) is changed. 7 and FIG.
Each corresponds to FIG. 4 used in the description of the first embodiment, and in these figures, the same reference numerals are given to the same components shown in FIGS. 1 to 5.

In both of these two modified examples, the opening (6) of the lower plate-shaped portion (3) is formed so that the respective side edges are covered with the cover member (10).
The cover member has concave portions (3a) and (3a) which are recessed corresponding to the thickness of each side edge portion of the cover member.
Two ribs (4) each inner edge of which is spaced apart
The point (4) is identical in that it has protrusions (10a) (10a) that come into contact with the side surfaces.

First, a modification shown in FIG. 7 will be described.

In FIG. 7, each of the opening portions (6) of the lower plate-shaped portion (3) is fitted with a cover member recessed corresponding to the thickness of each of the side edges of the cover member (10). Recess (3a)
(3a), when the cover member (10) is attached to the opening (6), the outer surface of the lower plate-shaped portion (3) and the cover member (1)
0) is made flush with the outer surface.

Further, each side edge on the inner surface side of the cover member (10) has projections (10a) (10a) that abut against opposing side surfaces of the two ribs (4) and (4) that are separated from each other. When the cover member (10) is attached to the opening (6), the cover member (10) is prevented from shifting in the width direction. Note that (4a) and (4a) correspond to each rib (4).
It is a projection fitting recess provided at the lower part of (4).

The cover member fitting recesses (3a) and (3)
a) and the projection fitting recess (4a) are formed along the length direction of the hollow material body (1), that is, in the extrusion direction, and are formed at the time of extrusion molding of the hollow material body (1). It has been done.

As in the first embodiment, the cover member (10) is inserted into the cover member fitting recesses (3a) (3a) of the lower plate portion (3) as shown in FIG. The respective side edges are fitted, and the cover member (10) is integrally joined and fixed at the overlapping portions (15) and (15) by friction stir welding. Thereby, the cover member (10)
The lower plate-shaped portion (3) is fixedly attached to the opening (6) of the lower plate-shaped portion (3).

In FIG. 8, the cover member (10)
Each of the side edge portions has a thick portion (10b) (10b) having a rectangular cross-section, which is formed to protrude inward and be thick. Further, each side edge on the inner surface side of the cover member (10) has projections (10a) (10a) that abut against opposing side surfaces of the two ribs (4) (4) separated from each other. Further, the thick portion (10a) and the protrusion (10b) are formed integrally.

The opening (6) of the lower plate-shaped portion (3) has a side edge portion corresponding to the thickness of each side edge portion of the cover member (10). 3a) and (3a) such that when the cover member (10) is attached to the opening (6), the outer surface of the lower plate-shaped portion (3) and the outer surface of the cover member (10) are flush. It has been done. In addition, the protrusion (10
a) (10a) covers the cover member (10) with the opening (6).
The cover member (10) is prevented from shifting in the width direction when the cover member (10) is mounted.

Then, as shown in the figure, the respective side edges of the cover member (10) are fitted into the cover member fitting concave portions (3a) (3a) of the lower plate-like portion (3), The member (10) is inserted into the cover member fitting recess (3a).
At the opposing portions (16) (16) of the upstanding surface portion (3a) and the side edge end surface portion of the cover member (10), they are integrally fixed by friction stir welding. Thus, the cover member (19) is fixedly mounted on the opening (6) of the lower plate-shaped portion (3).

FIGS. 9 to 11 illustrate the second embodiment of the present invention. This embodiment is shown in FIG.
This shows a case where a hollow material having four hollow portions is manufactured by using a wide hollow material main body (1) having a cross-sectional shape shown in FIG. 0 and a flat cover member (10). The hollow material body (1) and the cover member (10) are both made of aluminum. Further, the hollow material main body (1) and the cover member (10) in the same figure are formed into a flat shape by being developed together as described later. 9 to 11
, The same components as those shown in FIGS. 1 to 5 are denoted by the same reference numerals.

In the hollow material main body (1), the lower plate-shaped portion (3) serving as the lower outer plate portion (33) of the hollow material does not exist because the entire opening (6) is formed. It has been done. Then, with the disappearance of the lower plate portion (3), all the four hollow portions have also disappeared. (4b)... Are joining pieces provided along the length direction at the lower end of each rib (4).

In this embodiment, by covering the hollow member body (1) with the cover member (10) fixedly, all the disappeared hollow portions are restored, and the hollow member is restored in the width direction.
It is intended to produce a hollow material having a plurality of hollow portions.

The method for manufacturing such a hollow member will be described along the manufacturing steps.

First, similarly to the first embodiment, a hollow material body (1) having an inverted V-shaped cross section as shown in FIG.
Is produced by extrusion molding. That is, by extrusion molding, an upper plate-like portion (2) for forming an upper outer plate portion (32) having a bent portion (A) at an intermediate portion in the width direction, and the partition portion (3).
4) forming ribs (4) ... and there is no lower plate-shaped portion (3) for forming the lower outer plate portion (33) at the portion facing the bent portion (A). A hollow material body (1) having an opening (6) is manufactured.

Then, similarly to the first embodiment, this hollow material main body (1) is connected to a known unfolding apparatus (not shown).
And flattening is performed at the bent portion (A). Next, as shown in FIG. 10, the cover member (10) is attached to the opening (6). When the vibration damping material is loaded, after the vibration damping material is loaded from the opening (6), the cover member (10) is fixedly attached to the opening (6).

The cover member (10) is formed into a flat plate shape by performing the expansion process as described above, and has a width corresponding to the width of the upper plate portion (2). In addition, it is made of a long flat plate formed so that the length corresponds to the length of the upper plate-shaped portion (2).

Then, the inner surface of the cover member (10) is superimposed on the joint pieces (4b) of the ribs (4).
As shown in FIG. 1, the cover member (10) is integrally joined and fixed at these superposed portions (15) by friction stir welding. Thereby, the cover member (10) is fixedly mounted on the hollow material main body (1), and an intended hollow material having four hollow portions in the width direction is manufactured.

Although the embodiments of the present invention have been described above, the present invention is not limited to these embodiments. For example, in the above embodiment, the cover member (1
0) uses an extruded material or a material that has been developed, but in the present invention, other than this, a rolled material, a cast material, or the like may be used. Further, in the above embodiment, the plate-like portion (2) for forming one outer plate portion (32) has only one bent portion (A) in the width direction. However, in the present invention, the bent portion (A) is provided. (A) may be plural in the width direction. However, in this case, it is necessary to form an opening (6) in which at least the other plate-shaped portion (3) does not exist, at least at a portion facing the bent portion (A). Further, claim 1
In the inventions of (1) to (3), the joining and fixing of the cover member (10) to the opening (6) may be performed by various kinds of welding such as argon arc welding or brazing.

[0055]

As described above, the method for manufacturing a hollow member according to the present invention has the following effects. According to the first aspect, the one outer plate portion forming plate-shaped portion having a bent portion in at least a part of the width direction, and the partition portion forming rib portion are provided, and at least the bent portion is opposed. The part is manufactured by extrusion molding a hollow material body having an opening formed without the other outer plate portion forming plate-shaped portion. It is not necessary to use a large die, and the design and production of the die become easy, and the production cost is reduced. Also, due to the presence of the opening, even when the hollow material main body is subjected to the unfolding process, one of the two plate-shaped portions is pulled at the bent portion and the other is not compressed, and the hollow material main body is flattened. It can be formed into a shape. Therefore, it is possible to easily produce a wide hollow material which has been difficult in the conventional extrusion. Further, when the vibration damping material is loaded in the hollow portion, the vibration damping material is loaded into the hollow portion by installing the cover member after loading the vibration damping material from the opening of the plate portion. Therefore, the operation of loading the vibration damping material can be easily performed.

According to a second aspect of the present invention, each side edge of the opening of the plate-shaped portion has a concave portion for fitting a cover member which is depressed corresponding to the thickness of each side edge of the cover member. Therefore, when the cover member is attached to the opening, the outer surface of the outer plate portion is flush with the outer surface of the cover member, and the outer surface of the hollow member can be flattened. For this reason, the obtained hollow material can be suitably used as a constituent member such as a floor material, a wall material, and a ceiling material.

According to a third aspect of the present invention, each side edge on the inner surface side of the cover member has a projection which comes into contact with the side surface of the rib portion. The portion abuts on the side surface of the rib portion to prevent lateral displacement in the width direction.

According to the fourth aspect of the present invention, since the cover member is fixedly joined by friction stir welding, the strength of the weld heat affected zone such as MIG welding or TIG welding is reduced, thermal distortion is generated, and the metal constituting the hollow material is formed. The inconvenience of being restricted by the type is avoided, and the cover member can be securely fixed.

[Brief description of the drawings]

FIG. 1 is a view showing a cross-sectional shape when a hollow material body according to a first embodiment of the present invention is extruded.

FIG. 2 is a perspective view showing a hollow member body formed by flattening the hollow member body by subjecting the hollow member body to a development process, and a cover member.

FIG. 3 is a sectional view taken along line III-III in FIG. 2;

FIG. 4 is a cross-sectional view showing a state where a cover member is attached to an opening.

FIG. 5 is a sectional view showing a state in which the cover member is fixedly joined by friction stir welding.

FIG. 6 is a diagram showing a modification of the hollow material body of the first embodiment.
It is sectional drawing corresponding to FIG.

FIG. 7 is a cross-sectional view corresponding to FIG. 4 showing one modified example in which the shape of each side edge of the opening of the lower outer plate and the shape of each side edge of the cover member are changed.

8 is a cross-sectional view corresponding to FIG. 4, showing another modified example in which the shape of each side edge of the opening of the lower outer plate and the shape of each side edge of the cover member are changed.

FIG. 9 is a diagram showing a cross-sectional shape when extruding a hollow material body according to a second embodiment.

FIG. 10 is a cross-sectional view showing a hollow member body formed by flattening the hollow member body by subjecting the hollow member body to a development process, and a cover member.

FIG. 11 is a sectional view showing a state in which the cover member is fixedly joined by friction stir welding.

FIG. 12 is an explanatory perspective view of a hollow member.

[Explanation of symbols]

 A: Bent part 1: Hollow material body 2, 3, Plate part 4: Rib part 5: Hollow part 6: Opening part 10: Cover member 10a: Protrusion part 20: Friction stir welding device 21: Rotor 22: Probe 31 ... hollow materials 32, 33 ... outer plate part 34 ... partition wall part 35 ... hollow part

Claims (4)

[Claims] 1. A plurality of partition walls (32) partitioning a space between two flat outer plates (32) and (33), which are spaced apart in parallel, and a space between the outer plates (32) and (33). 34) is a method of manufacturing a hollow material (31) for manufacturing a hollow material (31) continuously formed in the length direction, wherein the one of the outer materials has a bent portion (A) in at least a part of the width direction. It has a plate-shaped portion (2) for forming a plate portion, and a rib portion (4) for forming the partition portion, and at least a portion of the other outer plate portion which is opposed to the bent portion (A) is formed. A hollow material body (1) in which an opening (6) in which no plate-shaped portion (3) is present is formed by extrusion molding, and the hollow material body (1) is formed at the bent portion (A). A method of manufacturing a hollow material, comprising: after flattening and developing a cover member (10) in a fixed state in the opening (6). 2. An opening (6) of the plate-like portion (3) for fitting a cover member recessed at each side edge corresponding to the thickness of each side edge of the cover member (10). The method for producing a hollow member according to claim 1, wherein the hollow member has concave portions (3a). 3. A projection (10a) in which each side edge of the inner surface of the cover member (10) is in contact with a side surface of the rib (4).
The method for producing a hollow material according to claim 1 or 2, wherein (10a) is provided. 4. The method for manufacturing a hollow member according to claim 1, wherein the cover member is fixedly joined by friction stir welding.