JPH1061435A - Muffler and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To secure high airtightness in a method being of advantage of a cost, by forming an annular groove in the peripheral surface of a cover member for closing the opening of the end part of a muffler outer cylinder, and caulking the peripheral wall of the end part of the muffler outer cylinder to the peripheral part of the cover member after the end part of the muffler outer cylinder is fitted under a condition that this annular groove is covered with. SOLUTION: Both end parts of a muffler outer cylinder 1 are fitted to the fitting cylindrical parts 5, 8 of respective lid member 2, 3 on an engine side and an exhaust side under a condition that annular grooves 7, 10 are covered which are formed in the peripheries of the fitting cylindrical parts 5, 8. Then, the whole circumference of the circumferential walls 11, 13 of the end parts of the outer cylinder 1 are caulked to the peripheral surfaces of the fitting cylindrical parts 5, 8 of the lid members 2, 3, and plastically deformed 12, 14 in the whole circumference of the annular grooves 7, 10, thereby the muffler outer cylinder 1 and the cover members 2, 3 are jointed and integrated with each other. At this time, the caulking and plastic deformation of the circumferential walls 11, 13 of the end parts of the muffle outer cylinder 1 are preferably executed by an electromagnetic forming device. Blemishes and so on generated in a case of mechanical caulking may not occur by electromagnetic forming, and besides, high sealed properties can be secured.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a motorcycle,
The present invention relates to a muffler used as a muffler for a vehicle engine such as an automobile and a truck, and a method for manufacturing the same.

[0002]

2. Description of the Related Art As shown in FIG. 3, a conventional muffler used in motorcycles and automobiles, for example, is a muffler outer cylinder (51) made of an aluminum alloy manufactured by impact molding. ) Is closed with an aluminum alloy lid (52) manufactured by casting, forging or cutting, and the outer cylinder (51) and the lid (5) are closed.
2) is integrated by welding (53).

[0003] However, in the method of joining the outer cylinder (51) and the lid member (52) by welding, the joining is very troublesome, such as welding must be performed over the entire circumference.
There was a disadvantage that the manufacturing cost was high.

On the other hand, when the muffler outer cylinder is fixedly supported on a support, a structure is known in which the muffler outer cylinder is fixed by partially caulking it at arbitrary locations (Japanese Utility Model Publication No. 56-9055). Column 2 lines 30-34 and FIG. 2).

[0005] Therefore, by utilizing this technology,
It is conceivable that the outer cylinder (51) is partially caulked at any number of places to the lid material (52) to join them together.

However, in this case, since the swaged portion is partial, a gap is formed between the outer cylinder (51) and the lid member (52), so that the performance as a muffler requiring airtightness is secured. There was a drawback that it was difficult to do.

The present invention has been made in view of the above technical background, and can ensure high airtightness in a joint state between a muffler outer cylinder and a lid member, and can be manufactured at a low cost. It is an object of the present invention to provide a muffler having a structure that can be used and a method for manufacturing the same.

[0008]

In order to achieve the above object, the muffler of the present invention comprises a metal muffler outer cylinder, and a lid member for closing an end opening of the muffler outer cylinder. In a mode in which the outer peripheral surface has an annular groove extending in the circumferential direction, and the annular groove is covered with an end peripheral wall of the muffler outer cylinder, the annular groove is fitted into the end of the muffler outer cylinder in an internally fitted state, and The end peripheral wall of the cylinder is crimped to the outer peripheral portion of the lid material over the entire circumference, and the peripheral wall is plastically deformed into the annular groove of the lid material, so that the muffler outer cylinder and the lid material are joined and integrated. It is characterized by the following.

As described above, the end peripheral wall of the muffler outer cylinder is crimped to the outer peripheral portion of the lid material over the entire circumference, and the peripheral wall is plastically deformed into the annular groove of the lid material. Since the material is joined and integrated, high airtightness between the muffler outer cylinder and the cover material is ensured.

In addition, since the joining is performed by caulking, the joining is easy, the muffler can be manufactured in an advantageous manner in terms of cost, and the quality can be improved without consuming a large amount of energy as in the case of welding. It is also stable in terms of surface.

Further, when the end peripheral wall of the muffler outer cylinder is caulked and plastically deformed by electromagnetic forming, there is no occurrence of scratches and the like which are observed in the case of mechanical caulking, and the appearance is extremely high. In addition to the advantage, there is no inconvenience that the equipment becomes complicated to prevent liquid leakage as seen when hydraulic pressure such as hydraulic pressure is used, and an even force acts on the peripheral wall at the end of the muffler outer cylinder. The peripheral wall of the end of the cylinder is securely crimped to the outer periphery of the lid material over its entire circumference, and is plastically deformed in the annular groove, so that a high-quality, highly airtight joint can be obtained. Not only that, this bonding can be performed in a short time, the productivity is improved, and the manufacturing is more advantageously performed in terms of cost.

Further, the muffler outer cylinder is made of a pipe material,
Lids are fitted into the openings at both ends, and when the peripheral walls at both ends of the muffler outer cylinder are caulked to the outer periphery of each lid, the length of the pipe material is freely set. , And various mufflers with different capacities.

[0013]

Next, an embodiment of the present invention will be described.

In FIG. 1 showing a muffler according to the embodiment, (1) is a muffler outer cylinder, (2) is a cover material on the engine side, and (3) is a cover material on the exhaust side.

The muffler outer cylinder (1) is made of, for example, A6061.
It is made of an aluminum drawn tube made of an alloy or the like, and its dimensions are designed to be, for example, 125 mm in diameter, 1.2 mm in wall thickness, and 500 mm in length. Note that the length of the muffler outer cylinder (1) may be appropriately set according to the intended muffler capacity. The setting of the length of the muffler outer cylinder (1) can be easily dealt with by changing the length of the drawing tube constituting the same.

The cover member (2) on the engine side is a forged product or a cast product made of, for example, the same aluminum as the muffler outer cylinder (1) made of A6061 alloy or the like. The lid (2) has a hole (4) to which a pipe from the engine side is connected, and a fitting cylindrical part (5) is integrally formed at the end on the muffler outer cylinder (1) side. The fitting tubular portion (5) is formed so as to be fitted to the end of the muffler outer cylinder (1) in a state of being fitted inside. An annular stepped portion (6) for positioning the end surface of the muffler outer cylinder (1) is formed on the outer peripheral side of the base end of the fitting cylindrical portion (5). An annular groove (7) extending all around in the circumferential direction is provided in a middle portion in the longitudinal direction of the outer peripheral surface of the fitting cylindrical portion (5).
Are formed.

The lid member (3) on the exhaust side is also a forged product or a cast product made of the same aluminum as the muffler outer cylinder (1), for example, made of A6061 alloy or the like. The lid material (3)
Has a hole (9) to which an exhaust pipe is connected, and a fitting cylindrical portion (8) is formed at the end on the muffler outer cylinder (1) side by integral molding. 8) is adapted to be fitted to the other end of the muffler outer cylinder (1) in a state of being fitted inside. An annular groove (10) extending in the entire circumferential direction is provided at the intermediate portion in the length direction of the outer peripheral surface.
Are formed.

At one end of the muffler outer cylinder (1), a fitting cylindrical portion (5) of the engine-side lid (2) is fitted with its annular groove (7). 1) One end peripheral wall (11)
And is fitted in an inner fitting state. The entire circumference of the one end peripheral wall (11) of the outer cylinder (1) is
It is crimped on the outer peripheral surface of the fitting cylindrical portion (5) of the lid material (2) and plastically deforms (12) within the entire circumference of the annular groove (6).
Then, the muffler outer cylinder (1) and the lid member (2) are joined and integrated. At the other end of the muffler outer cylinder (1), a fitting cylindrical portion (8) of the exhaust-side lid member (3) has an annular groove (10) formed at the end of the outer cylinder (1). It is fitted in an inner fitting state so as to be covered by the peripheral wall (13). Then, the entire periphery of the end peripheral wall (13) is caulked to the outer peripheral surface of the lid member (3), and is plastically deformed (14) within the entire periphery of the annular groove (10). It is joined and integrated with the tube (1).

The above muffler is manufactured as follows. That is, the muffler outer cylinder (1) having the above-described configuration and the two lid members (2) and (3) are manufactured and prepared, and the electromagnetic molding device (15) is prepared.

The electromagnetic forming device (15) is a forming device for a contracted tube. As shown in FIGS. 2 (a) and 2 (b), a forming coil (16) having a size in which a workpiece can be inserted and arranged therein is provided. The molded coil (16) is connected to an electric circuit interposed with a switch (17), a capacitor (19), and the like, and the workpiece is inserted and arranged in the coil (16). When a large instantaneous current is applied to the coil (16), magnetic repulsion is generated between the workpiece and the formed coil (16), and the workpiece is reduced in size by the magnetic repulsion. is there.

The joining on the engine side is performed as follows.
That is, as shown in FIG. 2A, a fitting cylindrical portion (5) of the engine-side lid member (2) is provided at one end of the outer cylinder (1).
Is fitted in an inner fitting state, and a shape restraining jig (20) is inserted from the other end side of the outer cylinder (1), and this is inserted into the fitting cylindrical portion (5) of the lid member (2). Insert and place in a suitable state. Thereafter, using the electromagnetic forming apparatus (15), the end of the outer cylinder (1) is inserted and arranged in the formed coil (16), and the coil (1) is inserted.
By passing a large instantaneous current in 6), a force in the contraction direction is applied to the end of the outer cylinder (1) by its magnetic repulsion. As a result, the end peripheral wall (11) of the outer cylinder (1) is swaged to the outer peripheral surface of the fitting cylindrical portion (5) of the lid member (2), and the annular projecting into the annular groove (7). The plastically deformed part (12) of the muffler is formed instantaneously, and the muffler outer cylinder (1) and the lid material (2)
Are joined and integrated.

Next, for joining the end on the exhaust side, first, after extracting the shape-restricting jig (20), the lid (3) on the exhaust side is attached to the other end of the outer cylinder (1). The fitting tubular portion (8) is fitted in an inner fitting state. Then, the electromagnetic forming device (1
Similarly, the end of the outer cylinder (1) is inserted into the formed coil (16) and the instantaneous large current flows through the coil (16). Tube (1)
The end peripheral wall (13) is crimped on the outer peripheral surface of the lid member (3) to form an annular plastically deformed portion (12) projecting into the annular groove (10), and the muffler outer cylinder (1) And the lid material (3)
Are joined and integrated.

As described above, a muffler in which both ends of the outer cylinder (1) are closed by the lids (2) and (3) is manufactured. Since the pressure inside the muffler is about 3 kgf / cm ² during operation of the engine, the muffler outer cylinder (1) and the lids (2) (3) are used to further ensure the airtightness inside the muffler.
It is preferable that a metal gasket or the like is interposed between these. Although not shown, a silencing member such as a perforated pipe and a sound absorbing material is provided inside the muffler.

As described above, in the above embodiment,
Lid members (2) and (3) are fitted into the end portion of the metal muffler outer cylinder (1) in an in-fit state, and the end peripheral wall (11) of the outer cylinder (1) is fitted.
The outer cylinder (1) and the lid members (2) and (3) are joined and integrated by crimping (13) on the outer periphery of the lid members (2) and (3) over the entire circumference. The lid members (2) and (3) having the fitting portions (5) and (8) have annular grooves (7) and (10) extending in the circumferential direction on the outer peripheral surface thereof. Cover the peripheral walls (11) and (13) with the annular grooves (7) (10) in the lids (2) and (3).
Since the outer cylinder (1) and the lids (2) and (3) are joined and integrated by plastic deformation (12) and (14) inward, the joint of these two joints must be airtight. Good and stable for a long time.

Moreover, since the joining is performed by caulking, the joining is easy, and the muffler can be manufactured in an advantageous manner in terms of cost, and the quality does not consume much energy as in the case of welding. Surface stability can also be improved.

In addition, in the above embodiment, the caulking is performed by using the electromagnetic forming device (15), so that the end peripheral walls (11) and (13) of the outer cylinder (1) extend over the entire circumference thereof. A uniform force is applied in the axial direction, and the lid material (2) (3)
And securely plastically deformed (12) and (14) in the annular grooves (2) and (3) to obtain a high quality and strong joint. Not only that, this joining can be performed instantaneously, thereby improving the productivity and further reducing the cost of the product. In addition, there is no scratch on the surface as in the case of mechanical caulking, which is extremely advantageous from the aesthetic standpoint, and the equipment is complicated to prevent liquid leakage such as when hydraulic pressure such as hydraulic pressure is used. It does not need to be changed, and simple and small equipment is sufficient. In the illustrated embodiment, it has been described that the two members (2) and (3) are separately subjected to electromagnetic molding, but may be simultaneously performed by one molding device.

Further, in the above embodiment, since the muffler outer cylinder (1) is made of a drawn tube, there is no wrinkle as in the case of the conventional impact molding, and the surface can be mirror-finished. In addition, the dimensional accuracy of the outer cylinder (1) is also improved, so that the quality of the joint with the lid members (2) and (3) can be improved, and a large muffler outer cylinder (1) that is difficult to perform by impact molding. Can also be easily manufactured. Note that an extruded tube may be used as the muffler outer cylinder (1).

[0028]

As described above, according to the muffler of the present invention, the cover material is fitted to the end of the metal muffler outer cylinder in an in-fit state, and the peripheral wall of the end of the outer cylinder is formed over the entire circumference. The outer cylinder and the lid member are joined and integrated by being crimped to the outer peripheral portion, and the lid member has an annular groove extending in the circumferential direction on the outer peripheral surface thereof, and the end peripheral wall of the outer cylinder is provided. Is plastically deformed inside the annular groove of the lid member and the outer cylinder and the lid member are joined and integrated, so that high airtightness between the outer cylinder and the lid member can be secured.

Further, since the joining is performed by caulking, the joining is easy, and the muffler can be manufactured in a cost-effective manner, and the quality can be reduced without consuming a lot of energy as in the case of welding. Surface stability can also be improved.

Further, when caulking and plastic deformation of the peripheral wall at the end of the muffler outer cylinder are performed by electromagnetic molding, there is no occurrence of scratches and the like seen in the case of mechanical caulking, and the appearance is extremely high. It is advantageous, and it is possible to apply an even force to the peripheral wall at the end of the muffler outer cylinder without inconvenience of complicating the equipment in order to prevent liquid leakage such as when using hydraulic pressure such as hydraulic pressure. The outer peripheral end wall of the outer cylinder,
The entire periphery can be securely crimped to the outer peripheral portion of the lid member and plastically deformed in the annular groove, so that a high quality airtight joint having extremely high airtightness can be obtained. Not only that, this bonding can be performed in a short time, the productivity can be improved, and the manufacturing can be more advantageously performed in terms of cost.

Also, the muffler outer cylinder is made of a pipe material,
Lids are fitted into the openings at both ends, and when the peripheral walls at both ends of the muffler outer cylinder are caulked to the outer periphery of each lid, the length of the pipe material is freely set. Thus, it becomes easy to provide various mufflers having different capacities.

Further, according to the method for manufacturing a muffler according to the present invention, a muffler having a good joint between the outer cylinder and the lid member can be efficiently manufactured.

[Brief description of the drawings]

FIG. 1 shows a muffler according to an embodiment, wherein FIG. 1A is a longitudinal sectional view, FIG. 1B is a sectional view taken along line II of FIG. 1A, and FIG. FIG. 2 is a sectional view taken along line II-II.

FIGS. 2A and 2B show a method of manufacturing a muffler. FIG. 2A is a longitudinal sectional view showing a joining method of a lid material on one end, and FIG. 2B is a longitudinal sectional view showing a joining method of another lid material. is there.

FIG. 3 is a longitudinal sectional view of a conventional muffler.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Muffler outer cylinder 2, 3 ... Lid material 7, 10 ... Annular groove 11, 13 ... End peripheral wall 12, 14 ... Plastic deformation part

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Yuichi Takami 6,224, Kaiyama-cho, Sakai City Showa Aluminum Co., Ltd. 72) Inventor Sadao Kokubo, 224 Kaiyamacho, Sakai City, Showa Aluminum Co., Ltd.

Claims (4)

[Claims] 1. A muffler outer cylinder made of metal, and a lid member closing an end opening of the muffler outer cylinder, the lid member has an annular groove extending in a circumferential direction on an outer peripheral surface thereof,
In the aspect in which the annular groove is covered by the end peripheral wall of the muffler outer cylinder, the annular groove is fitted in an end-fit state at the end of the muffler outer cylinder,
In addition, the end peripheral wall of the muffler outer cylinder is crimped to the outer peripheral portion of the lid material over the entire circumference, and the peripheral wall is plastically deformed into the annular groove of the lid material, so that the muffler outer cylinder and the lid material are integrally joined. A muffler characterized by being made into a muffler. 2. The caulking and plastic deformation of the peripheral wall at the end of the muffler outer cylinder are performed by electromagnetic forming.
The muffler described in. 3. The muffler outer cylinder is made of a pipe material, and lids are fitted into openings at both ends thereof, and peripheral walls at both ends of the muffler outer cylinder are crimped to outer peripheral portions of the respective lids. Or the muffler according to 2. 4. A muffler outer cylinder made of metal and a lid fitted inside the end of the muffler outer cylinder so as to be fitted into the end of the muffler outer cylinder. Manufactured to have a groove, a lid material is fitted to the end of the muffler outer cylinder so that the annular groove is covered by the peripheral wall at the end of the muffler outer cylinder, and then, in this combined state, By electromagnetic forming, the end peripheral wall of the muffler outer cylinder is crimped to the outer peripheral portion of the lid material, and the peripheral wall is plastically deformed into the annular groove of the lid material, thereby joining and integrating the muffler outer cylinder and the lid material. A method for producing a muffler.