WO2018092345A1

WO2018092345A1 - Production method for metal component and metal component production device

Info

Publication number: WO2018092345A1
Application number: PCT/JP2017/022922
Authority: WO
Inventors: 稔正山根; 一成上原
Original assignee: 株式会社キーレックス
Priority date: 2016-11-15
Filing date: 2017-06-21
Publication date: 2018-05-24
Also published as: JP6739795B2; JP2018079774A

Abstract

According to the present invention, a jig (5) includes a flexible body (56) that vibratably attaches a plurality of reference pins (57) to a jig main body (51). A panel-shaped first metal body (2) and a panel-shaped second metal body (4) are mounted, in order, on the jig main body (51) such that the reference pins (57) fit into first fitting holes (22b) in the first metal body (2) and second fitting holes (42b) in the second metal body (4). An ultrasonic joining machine (6) is used to form a solid joining part (W1) at overlapping overlap parts (2b, 4b) of the first metal body (2) and the second metal body (4), and the first metal body (2) and the second metal body (4) are thereby integrated.

Description

Metal part manufacturing method and metal part manufacturing apparatus

The present invention relates to a manufacturing method or a manufacturing apparatus for manufacturing a metal part to be assembled to a vehicle from two panel-like metal bodies, for example.

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

By the way, in the insulator as in Patent Document 1, for the purpose of improving the material yield and reducing the weight, the outer peripheral portion of the first metal body and the outer peripheral portion of the second metal body are joined to each other without folding the outer peripheral portion of the first metal body. Therefore, there is a demand for integrating the first metal body and the second metal body, and as the joining method, it is possible to apply an ultrasonic joining method in which the appearance of the insulator after completion is hardly affected by thermal distortion. Conceivable.

JP 2006-519710 A

However, in the ultrasonic bonding method, minute vibrations are applied to the bonding portion during bonding, so in the metal body to be bonded, for example, the ultrasonic wave is applied to a portion having a highly rigid portion such as a reference hole for positioning with respect to a jig. When vibration propagates, there is a risk that cracks and cracks may occur due to repeated application of load to the location.

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

In order to achieve the above object, the present invention is characterized in that a reference pin for positioning a jig used for ultrasonic bonding can be vibrated.

That is, in the first invention, ultrasonic bonding is possible with a jig main body installed on the floor, a plurality of reference pins, and a jig having pin attachment means for attaching the reference pins to the jig main body so as to be able to vibrate. Ultrasonic bonding means, and two panel-like metal bodies each having a plurality of fitting holes corresponding to the reference pins, and the reference pins to the fitting holes of the metal bodies. The metal bodies are placed on the jig main body in order so as to be fitted, and a joining part is formed by the ultrasonic joining means at an overlapping portion of the metal bodies to obtain a metal part integrally. It is characterized by that.

The second invention is characterized in that, in the first invention, the pin mounting means is an elastic body made of a rubber material.

Further, the present invention comprises a jig main body and a jig having a plurality of reference pins installed on the floor, and ultrasonic bonding means arranged on the side of the jig and capable of ultrasonic bonding, The two metal plates are formed in order so that the reference pins fit into the fitting holes of the metal bodies, respectively, in the two panel-like metal bodies formed with a plurality of fitting holes corresponding to the reference pins. In addition, a metal part manufacturing apparatus configured to obtain a metal part integrally by forming a joint with the ultrasonic joining means on the overlapping part of the metal bodies while being placed on the jig body. Targeted the following solutions.

That is, in the third aspect of the invention, the jig body includes pin attachment means for attaching the reference pins to the jig body so as to vibrate.

The fourth invention is characterized in that, in the third invention, the pin mounting means is an elastic body made of a rubber material.

In the first and third inventions, each metal body is placed on the jig body in order so that the two metal bodies are fitted in the respective fitting holes of the respective metal bodies. When ultrasonic bonding is performed on the overlapping portions by the ultrasonic bonding means, fine vibration propagates to the entire area of each metal body, but each of the pin mounting means vibrates in accordance with the vibration. Therefore, the two metal bodies placed on the jig vibrate in synchronism with the ultrasonic vibration, and it is difficult to repeatedly apply a load to the highly rigid portions of the two metal bodies, and cracks and cracks are caused. Occurrence can be suppressed.

In the second and fourth inventions, since the reference pin vibrates corresponding to ultrasonic vibration with a simple structure, metal parts can be manufactured by ultrasonic bonding with a low-cost apparatus.

It is a perspective view of the insulator manufactured with the manufacturing device concerning the embodiment of the present invention. FIG. 2 is a cross-sectional view taken along line II-II in FIG. It is the schematic of the manufacturing apparatus which concerns on embodiment of this invention, and shows the state which mounted two metal bodies and the sound-absorbing heat shield on the jig | tool used when manufacturing an insulator. It is the IV section enlarged view of FIG.

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

1 and 2 show an insulator 1 (metal part) according to an embodiment of the present invention. The insulator 1 is attached to the lower surface of a floor pan F1 of a vehicle for the purpose of heat insulation and sound insulation against heat and noise generated from exhaust system parts and drive system parts, and the insulator manufacturing apparatus shown in FIGS. 3 and 4 10 (metal parts manufacturing apparatus).

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

second metal bodies

2 and 4 in FIGS. 1 to 4 is exaggerated for convenience.

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

Each inclined surface portion 22 is formed with a pair of circular first seating surface portions 22a with a predetermined interval in the vehicle front-rear direction in a plan view that projects upward and the projecting surface extends horizontally. A first fitting hole 22b is formed through the center of the one seat surface portion 22a.

In the first metal body 2, the overlapping portion 2 b that overlaps the second metal body 4 when the second metal body 4 is assembled is provided on the outer side of the four first seat surface portions 22 a. A large number of through-holes 2 c are formed in a portion surrounded by the four first seat surface portions 22 a in the metal body 2.

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

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

A portion of the second metal body 4 outside the four second seating surface portions 42a is provided with a superposed portion 4b that overlaps the superposed portion 2b when assembled to the first metal body 2, and the second metal body. 4, a space forming portion 4a is formed in a portion surrounded by the four second seating surface portions 42a. The space forming portion 4a protrudes upward from the overlapping portion 4b.

And when the said 2nd metal body 4 is assembled | attached to the said 1st metal body 2, while the superposition | polymerization part 2b of the said 1st metal body 2 and the superposition | polymerization part 4b of the said 2nd metal body 4 overlap, the said 1st metal body An accommodation space layer S1 that accommodates the glass wool material 3 is formed between the space 2 and the space forming portion 4a of the second metal body 4.

Further, between the polymer part 2 b of the first metal body 2 and the polymer part 4 b of the second metal body 4, the polymer part 2 b of the first metal body 2 and the polymer part 4 b of the second metal body 4 are arranged. Are formed intermittently along the outer peripheral portions of the first and

second metal bodies

2, 4, and are formed by the solid phase joints W 1. The first metal body 2 and the second metal body 4 are integrated.

As shown in FIG. 3, the insulator manufacturing apparatus 10 includes a jig 5 for positioning the second metal body 4 with respect to the first metal body 2, and is disposed on the side of the jig 5 and is ultrasonically bonded. And an ultrasonic bonding machine 6 (ultrasonic bonding means) capable of performing the above.

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

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

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

A positioning unit 54 is attached to the upper part of each support frame 53.

As shown in FIG. 4, the positioning unit 54 includes a metal unit main body 55 formed with an accommodation recess 55a that opens obliquely upward on the ultrasonic bonding machine 6 side, and is substantially half on the bottom side of the accommodation recess 55a. Is fitted with an elastic body 56 (pin positioning means) made of a ring-shaped hard rubber material.

The housing recess 55a accommodates a reference pin 57 including a disk-shaped head portion 57a and a shaft portion 57b continuous to the head portion 57a, and the head portion 57a is in a posture in which the shaft portion 57b faces upward. Is fitted inside the elastic body 56, and the shaft portion 57b protrudes outward from the opening portion of the housing recess 55a.

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

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

Then, the second metal body 4 is placed so that the reference pins 57 are fitted into the second fitting holes 42b in a posture in which the side of the second metal body 4 to be assembled with the first metal body 2 faces upward. Place the glass wool material 3 on the jig body 51 and place the glass wool material 3 on the space forming portion 4a of the second metal body 4, and the side of the first metal body 2 to which the second metal body 4 is assembled. By placing the first metal body 2 on the jig body 51 so that the reference pins 57 are fitted into the first fitting holes 22b in a downward orientation, the first metal body 2 The first and

second metal bodies

2 and 4 are positioned in a state where the overlapping portion 2b and the overlapping portion 4b of the second metal body 4 overlap each other.

As shown in FIG. 3, the ultrasonic bonding machine 6 includes a pedestal 61 that can support both overlapping portions 2b and 4b in the first and

second metal bodies

2 and 4 positioned on the jig 5, and A vibration part 62 that is disposed above the pedestal part 61 and capable of ultrasonic vibration, and a pressure that lowers the vibration part 62 and sandwiches and pressurizes both the overlapping parts 2b and 4b with the pedestal part 61. Part 63, and when the pressure unit 63 pressurizes both the polymerized parts 2b and 4b between the pressure part 63 and the pedestal part 61, the vibration part 62 performs ultrasonic vibration, thereby the both polymerized parts. A solid phase junction W1 is formed between 2b and 4b.

Then, the ultrasonic bonding machine 6 moves the jig body 51 with a moving means (not shown) while positioning the overlapping portions 2b of the first and

second metal bodies

2 and 4 positioned by the jig body 51. The insulator 1 is obtained by integrating the first and

second metal bodies

2 and 4 by intermittently joining 4 b along the outer peripheral portions of the first and

second metal bodies

2 and 4.

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

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

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

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

Thereafter, while the jig body 51 is moved by a moving means (not shown), the ultrasonic bonding machine 6 causes the overlapping portions 2b and 4b of the first and

second metal bodies

2 and 4 positioned by the jig body 51 to move. The insulator 1 is obtained by integrating the first and

second metal bodies

2 and 4 by performing ultrasonic bonding intermittently along the outer peripheral portions of the first and

second metal bodies

2 and 4.

In addition, the joining conditions of the ultrasonic joining were set to a vibration frequency: 20 kHz, an amplitude of the vibration part 62: 0.06 mm, and a pressure applied by the pressure part 63: 1.5 kN.

As described above, according to the embodiment of the present invention, when ultrasonic bonding is performed to both the overlapping portions 2b and 4b, fine vibration propagates to the entire area of the first and

second metal bodies

2 and 4, but In addition, the elastic bodies 56 vibrate. Accordingly, the first and

second metal bodies

2 and 4 placed on the jig 5 vibrate in synchronization with the ultrasonic vibration, and the first and

second metal bodies

2 and 4 have high rigidity. Since it becomes difficult to apply a load repeatedly to a location, generation | occurrence | production of the crack in the 1st and

2nd metal bodies

2 and 4 and a crack can be suppressed.

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

In the embodiment of the present invention, when the first and

second metal bodies

2 and 4 are positioned on the jig body 51, the first fitting holes 22b and the

first metal bodies

2 and 4 of the first and

second metal bodies

2 and 4 are positioned. 2 The configuration is such that each reference pin 57 is only fitted into the fitting hole 42b, but the periphery of each first fitting hole 22b of the first metal body 2 is pressed by the claw member of the clamp mechanism. Also good.

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

In addition, each joint to be applied to the overlapping portions 2b and 4b of the first and

second metal bodies

2 and 4 is performed by transferring the first and

second metal bodies

2 and 4 to different jigs 5 in the middle of each joint. You may make it perform each remaining joining after mounting.

In addition, each joint to be applied to both overlapping portions 2b and 4b of the first and

second metal bodies

2 and 4 is a mechanism capable of changing the positioning posture provided in the jig 5 in the middle of each joint, or The industrial robot may change the posture of the first and

second metal bodies

2 and 4 by changing the inclination of the jig 5 itself, and then perform the remaining joints.

Moreover, in embodiment of this invention, although the insulator 1 is manufactured from the 1st metal body 2, the glass wool material 3, and the 2nd metal body 4 with the manufacturing method of this invention, it is not restricted to this, The manufacturing method of this invention Thus, other metal parts can be obtained by integrating two metal bodies having a panel shape.

The present invention is suitable, for example, for a manufacturing method or a manufacturing apparatus for manufacturing a metal part to be assembled to a vehicle from two panel-like metal bodies.

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

Claims

A jig body installed on the floor, a plurality of reference pins, a jig having a pin mounting means for attaching each of the reference pins to the jig body so as to vibrate, and an ultrasonic bonding means capable of ultrasonic bonding are prepared. And
Each metal body is mounted so that each reference pin is fitted into each fitting hole of each of the metal bodies, and two panel-like metal bodies each having a plurality of fitting holes corresponding to the respective reference pins are formed. Place them on the jig body in order,
A metal part manufacturing method characterized in that a metal part is obtained integrally by forming a joint part at an overlapping part of each metal body by the ultrasonic joining means.
In the manufacturing method of the metal component of Claim 1,
The pin mounting means is an elastic body made of a rubber material.
A jig body having a jig body and a plurality of reference pins installed on the floor;
An ultrasonic bonding means disposed on the side of the jig and capable of ultrasonic bonding;
Each metal body is mounted so that each reference pin is fitted into each fitting hole of each of the metal bodies, and two panel-like metal bodies each having a plurality of fitting holes corresponding to the respective reference pins are formed. A metal part manufacturing apparatus configured to obtain a metal part integrally by forming a joining part with the ultrasonic joining means in an overlapping part of the metal bodies in a state of being placed on the jig body in order. There,
The jig main body includes a pin mounting means for mounting the reference pins on the jig main body so that the reference pins can vibrate.
In the metal part manufacturing apparatus according to claim 3,
The pin mounting means is an elastic body made of a rubber material.