JP6414560B2 - Manufacturing method of structure - Google Patents

Description

  The present invention relates to a method for manufacturing a structure, and more particularly to a method for manufacturing a structure in which a working fluid control mechanism such as a transmission is housed.

  A case of a structure such as a transmission mounted on a vehicle is formed entirely using a metal material such as aluminum, but it is required to reduce the weight while ensuring a predetermined rigidity.

  On the other hand, a structure in which a part of a case of a metal structure is replaced with a resin and a metal frame member and a resin cover member are combined is known. For example, in Patent Document 1, a side cover that constitutes a part of a case of a transmission is configured by a metal frame member and a resin cover member that closes an opening formed between the frame members. Are disclosed.

JP 2013-117240 A

  As in the case disclosed in Patent Document 1, a frame member or the like for exclusively supporting the strength and rigidity of the frame member, a cover member for closing an opening surrounded by the bone part constituting the frame portion, and the like In the case of the wall surface portion, in order to further reduce the weight while securing the strength and rigidity, it is conceivable that the skeleton portion having the hollow structure is layered and formed by the three-dimensional layered manufacturing method.

  The three-dimensional additive manufacturing method here is based on CAD data and the like, and melts and solidifies by selectively irradiating a laser to a powder layer in which a powder of metal or the like is thinly spread, and a new powder layer is formed thereon. This is a method of manufacturing a three-dimensional shaped object in which a plurality of layers are laminated and integrated by repeating lamination and laser irradiation. According to this method, it is possible to integrally mold a product having a complicated internal structure such as a hollow structure that cannot be manufactured by molding using a mold.

  However, when layering a skeleton part having a hollow structure by such a three-dimensional additive manufacturing method, the powder that has not been melted and solidified remains in the cavity formed inside the skeleton part. In this case, it is necessary to remove this internal residual powder after shaping. This internal residual powder can be removed to some extent by sending compressed air from one of a plurality of discharge holes communicating with the cavity into the cavity and blowing out the internal residual powder together with air from the other discharge holes. However, it is difficult to completely remove the internal residual powder from the cavity, and the powder remains slightly inside. Therefore, when the structure is a transmission that houses a hydraulic control valve mechanism for controlling the working fluid, the internal residual powder that could not be removed leaks out from the cavity of the skeleton and enters the working fluid. The hydraulic actuator or the like supplied with the working fluid may cause malfunction. And this subject is not restricted to the case where a structure is a transmission.

  Then, an object of this invention is to provide the manufacturing method of a structure which can prevent that the internal residue of a structure leaks out of the exterior.

  In order to solve the above problems, the present invention is configured as follows.

First, the invention according to claim 1 of the present application is
A method of manufacturing a structure having a first member and a second member,
A first modeling step of modeling the first member having a cavity and a discharge hole for discharging the internal residue of the cavity by a three-dimensional additive manufacturing method;
A first removal step of removing the internal residue from the discharge hole of the first member;
A second modeling step of modeling the second member having a cavity and a discharge hole for discharging the internal residue of the cavity by a three-dimensional additive manufacturing method;
A second removal step of removing the internal residue from the discharge hole of the second member;
Assembling step of assembling the first member and the second member so that the discharge hole of the first member is closed by the second member and the discharge hole of the second member is closed by the first member . It is characterized by having.

The invention according to claim 2
A method of manufacturing a structure having a first member and a second member,
A first modeling step of modeling the first member having a cavity and a discharge hole for discharging the internal residue of the cavity by a three-dimensional additive manufacturing method;
A first removal step of removing the internal residue from the discharge hole of the first member;
A second modeling step of modeling the second member having a cavity and a discharge hole for discharging the internal residue of the cavity by a three-dimensional additive manufacturing method;
A second removal step of removing the internal residue from the discharge hole of the second member;
An assembling step of assembling the first member and the second member so that the discharge hole of the first member and the discharge hole of the second member are both closed by a welded portion.
It is characterized by that.

According to the invention described in claim 1 of the present application, the first and second members having a hollow portion and a discharge hole for discharging the internal residue of the hollow portion are formed by a three-dimensional additive manufacturing method, first, an internal residue is removed from the discharge hole of the second member, the first member so as to close the discharge hole of the second member by the first member with the discharge hole of the first member is closed by the second member And the second member are assembled, so that the internal residue that could not be removed does not leak to the outside through the closed discharge hole even if it tries to go out from the cavity of the first and second members . Therefore, it is possible to provide a method of manufacturing a structure that can prevent the internal residue of the structure from leaking to the outside.

Further, according to the invention of claim 2, the first and second members having a cavity and a discharge hole for discharging the internal residue of the cavity are formed by a three-dimensional additive manufacturing method, The first member and the second member are configured to remove the internal residue from the discharge holes of the first and second members, and to close the discharge holes of the first member and the discharge holes of the second member together by the welded portion. Therefore, even if the internal residue that could not be removed tries to go out from the cavity of the first and second members, it will not leak out through the closed discharge hole. Therefore, it is possible to provide a method of manufacturing a structure that can prevent the internal residue of the structure from leaking to the outside.

It is a top view of the structure concerning the 1st reference example . It is sectional drawing of the structure along the YY line in FIG. FIG. 3 is an enlarged cross-sectional view and a perspective view of a skeleton part in FIG. 2. It is sectional drawing of the case of the structure along the AA line in FIG. It is sectional drawing of the case of the structure along the BB line in FIG. It is sectional drawing of the modification of a frame | skeleton part. It is sectional drawing and the enlarged view of the structure which concerns on 1st Embodiment of this invention. It is sectional drawing and the enlarged view of the structure which concerns on 2nd Embodiment of this invention. It is sectional drawing and the enlarged view of the structure which concerns on a 2nd reference example .

  Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.

[First Reference Example ]
FIG. 1 is a top view of a structure according to a first reference example . FIG. 2 is a cross-sectional view of the structure taken along line YY in FIG.

[Structure of structure]
As shown in FIG. 1, the structure according to the first reference example is a transmission 1 that constitutes a power transmission device mounted on a vehicle, specifically, a front in which an input shaft and an output shaft are arranged on the same axis. This is a vertical-type transmission mounted on an engine / rear drive car.

  The transmission 1 includes a transmission mechanism arranged so that its axis extends in the longitudinal direction of the vehicle body, and a hydraulic control valve mechanism (not shown) for controlling the hydraulic pressure supplied to the transmission mechanism. Contained. The transmission mechanism includes an input shaft S1 connected via a clutch to a drive source such as an engine disposed on the vehicle body front side of the transmission case, and an output shaft disposed on the same axis as the input shaft S1. The input shaft S1 and the counter shaft S2 arranged in parallel to the output shaft, and the input shaft S1, the output shaft, and the counter shaft S2 are rotatably supported by the transmission case. FIG. 2 shows gears G1 and G2 provided on the input shaft S1 and the counter shaft S2 and meshing with each other.

  The transmission case that houses the above-described transmission mechanism includes a case body 2 on the front side of the vehicle body in which a clutch housing that houses a clutch and a transmission case that houses the transmission mechanism are integrally formed. An extension housing 3 on the rear side of the vehicle body connected thereto is provided as a case constituent member. This transmission case is formed by fastening and fixing a flange portion 2a provided on the vehicle body rear side of the case body portion 2 and a flange portion 3a provided on the vehicle body front side of the extension housing 3 using bolts and nuts. Has been.

  These case constituent members 2 and 3 have a skeleton portion 10 that forms a skeleton of the transmission case, and a wall surface portion 20 that is provided so as to close an opening surrounded by the skeleton portion 10. The skeleton part 10 includes a plurality of first skeleton parts 11 extending in the longitudinal direction of the vehicle body, which is the axial direction of the transmission case, and a plurality of second skeleton parts extending in the circumferential direction of the transmission case in a direction orthogonal to the axial direction of the transmission case. And a skeleton part 12.

  As shown in FIG. 2, a plurality of first skeleton parts 11 are provided apart from each other in the circumferential direction of the transmission case in the cross section in the direction orthogonal to the axial direction of the transmission case, and are formed in a substantially square shape in cross section. ing.

  3A is an enlarged cross-sectional view of the first skeleton part 11 shown in FIG. 2, and FIG. 3B is a perspective view in which a part of the first skeleton part 11 is cut away. As shown in FIG. 3A, the first skeleton portion 11 has an outer peripheral surface having a substantially square cross section, and has a skin layer 11a having a predetermined plate thickness, and is integrally formed inside the skin layer 11a. And a three-dimensional lattice structure portion 11b having a cavity portion 13 therein. In particular, in the case of the present embodiment, the lattice structure portion 11b has a diamond structure in which a plurality of unit lattices connecting the center of the regular tetrahedron and the four vertices are regularly coupled to each other.

  A plurality of second skeleton parts 12 are provided so as to be spaced apart in the axial direction of the transmission case and extend in the circumferential direction of the transmission case, and are formed in a substantially circular cross section. Although not shown in the drawing, the second skeleton portion 12 is formed by integrally forming a three-dimensional lattice structure portion having a hollow portion inside the skin layer forming the outer peripheral surface, similarly to the first skeleton portion 11.

  As shown in FIG. 6, the skeleton portion 10 may have a structure in which a plurality of holes extend in the longitudinal direction. At this time, for example, the ratio of the cross-sectional area of the plurality of hole portions 13 to the cross-sectional area of the skeleton portion 10 in the cross section intersecting the axial direction of the skeleton portion 10 is the inner periphery from the outer peripheral side of the skeleton portion 10. You may form so that it may become large as it goes to the side. In the case of such a modification, a predetermined rigidity is ensured as compared to the case where the ratio of the cross-sectional area of the plurality of holes 13 occupying the cross-sectional area of the skeleton part 10 is equal to the radial direction of the skeleton part 10. Therefore, the weight for reducing can be reduced.

  On the other hand, as shown in FIG. 2, the wall surface portion 20 is formed in a flat plate shape that is thinner than the skeleton portion 10. The wall surface portion 20 may have a structure in which a plurality of recesses are formed on at least one surface. According to this structure, the weight can be further reduced while ensuring the rigidity of the wall surface portion 20.

  Next, the structure around the mating surfaces 2b and 3b of the case main body 2 and the extension housing 3, which is a feature of this embodiment, will be described in detail with reference to FIGS. 4 and 5 are sectional views taken along lines AA and BB in FIG. 3, respectively.

  As shown in FIGS. 4 and 5, the case body 2 and the extension housing 3 are formed by connecting the mating surface 2 b of the case body 2, which is an end surface of the flange 2 a of the case body 2, and the flange 3 a of the extension housing 3. The mating surface 3b of the extension housing 3 which is the end surface is assembled in a state of being opposed to each other.

  At this time, as shown in FIG. 4, the discharge hole 11 c of the first skeleton portion 11 provided in the extension housing 3 opens in the mating surface 3 b of the flange portion 3 a, but is assembled to the extension housing 3. The case body 2 is closed by the mating surface 2b of the flange 2a. Therefore, the powder of metal or the like remaining inside the hollow portion 13 of the first skeleton portion 11 of the extension housing 3 does not leak out from the discharge hole 11c.

  Similarly, as shown in FIG. 5, the discharge hole 11 c of the first skeleton portion 11 provided in the case main body portion 2 opens in the mating surface 2 b of the flange portion 2 a, but is assembled to the case main body portion 2. The extension housing 3 is closed by the mating surface 3b of the flange portion 3a. Therefore, the powder of metal or the like remaining inside the hollow portion 13 of the first skeleton portion 11 of the case main body portion 2 does not leak out from the discharge hole 11c.

  Therefore, in the case of this embodiment, the case main body 2 and the extension housing 3 are assembled so as to close the discharge holes 11c and 11c at the mating surfaces 2b and 3b.

[Method of manufacturing structure]
The transmission 1 which is a structure configured as described above is manufactured by the following manufacturing method.

  First, using a 3D printer using, for example, a metal powder such as aluminum as a raw material, a modeling process is performed in which the frame portion 10 and the wall surface portion 20 of the transmission case are integrally layered by a three-dimensional layered modeling method.

  In this modeling process, when the skeleton part 10 of the transmission case is formed by the three-dimensional additive manufacturing method, the metal powder remaining in the hole part 13 is formed in the holes 13 and 14 formed in the skeleton part 10. In order to remove this, a discharge hole (not shown) communicating with the surface of the transmission case, preferably the inner peripheral surface, is formed.

  Here, as the three-dimensional additive manufacturing method, for example, based on CAD data, a powder sintering additive manufacturing method is used in which a material powder is sintered and formed one by one using a laser or an electron beam. obtain. Specifically, a powder layer in which a powder of metal or the like is spread thinly is melted and solidified by selectively irradiating with a laser or an electron beam, and a new powder layer is laminated thereon and laser irradiation is repeated. Powder Bed Fusion, which performs additive manufacturing, and Direct Energy Deposition (DMP), which melts by laser or electron beam while supplying powder and deposits the melt. ) Can be used. According to such a method, it is possible to integrally model a product having a complicated internal structure such as a hollow structure that cannot be manufactured by molding using a mold. Note that the three-dimensional additive manufacturing method is not limited to the above-described method.

  Next, a removal step is performed in which the metal powder remaining without being melted and solidified inside the cavities 13 and 14 formed in the skeleton 10 is removed from the discharge holes of the skeleton 10 to the outside of the cavities 13 and 14.

  Specifically, this removal is performed by sending compressed air from one of a plurality of discharge holes communicating with the cavities 13 and 14 into the cavities 13 and 14 and blowing out metal powder remaining together with the air from the other discharge holes. Then, vibration is applied to the transmission case after the layered manufacturing, and the metal powder remaining from the discharge hole is shaken off.

  In addition, after the removing step, a finishing step for performing cutting or the like on a necessary portion of the transmission case may be performed.

  Next, the case 1 is obtained by performing the assembling process of assembling each other by fastening and fixing the case constituent members 2 and 3 using bolts and nuts.

  Finally, a housing step for housing the hydraulic control valve mechanism is performed inside the obtained case 1.

  By the above manufacturing method, the transmission 1 which is the structure configured as described above is manufactured.

About the structure to which the present invention is applied, with reference to FIGS, specifically described.

[First Embodiment]
FIG. 7 is a cross-sectional view and an enlarged view of the gear assembly 101 which is a structure according to the first embodiment of the present invention. As shown in FIG. 7A, the gear assembly 101 includes an output gear 102 and a parking gear 103 that are assembled to each other concentrically with respect to the output shaft.

  Here, as shown in an enlarged view in FIG. 7B, the output gear 102 is provided with a cavity 102a and a discharge hole 102b communicating with the cavity 102a from the outside. Similarly, the parking gear 103 is provided with a discharge hole 103b communicating with the cavity 103a from the outside. The output gear 102 and the parking gear 103 are fixed to each other by a welded portion 104.

  At this time, the discharge hole 102 b of the output gear 102 is assembled so as to be closed by the inner peripheral portion of the parking gear 103, and the discharge hole 103 b of the parking gear 103 is closed by the flange surface of the output gear 102. Therefore, the powders such as metal remaining in the hollow portions 102a and 103a of the output gears 102 and 103 are blocked by the mating surfaces, so that the powder can be prevented from leaking to the outside.

[Second Embodiment]
FIG. 8 is a cross-sectional view and an enlarged view in the vicinity of one pinion constituting the planetary gear 201 which is a structure according to the second embodiment of the present invention. As shown in FIG. 8A, the planetary gear 201 includes a carrier 203 that rotatably supports the pinion shaft 202 and a gear 204 that is fixed to the carrier 203 by welding.

  Here, as shown in an enlarged view in FIG. 8B, the carrier 203 is provided with a cavity 203a and a discharge hole 203b communicating with the cavity 203a from the outside. Similarly, the gear 204 is provided with a hollow portion 204a and a discharge hole 204b communicating with the hollow portion 204a from the outside. The carrier 203 and the gear 204 are fixed to each other by a welded meat portion 205.

  At this time, both the discharge hole 203 b of the carrier 203 and the discharge hole 204 b of the gear 204 are assembled so as to be closed by the welded meat portion 205. Therefore, the powder of metal or the like remaining inside the cavity 203a of the carrier 203 and the cavity 204a of the gear 204 is blocked by the welded meat portion, so that this powder can be prevented from leaking outside. .

FIG. 9 is a cross-sectional view and an enlarged view of a differential gear 301 that is a structure according to a second reference example . As shown in FIG. 9A, the differential gear 301 includes a ring gear 302, a differential case 303 formed integrally with the ring gear 302, and a pinion shaft 305 fixed to the differential case 303 by a fixing pin 304. ,have. As shown in FIG. 9B, the ring gear 302 is fixed by a fixing pin 304.

  Here, as shown in an enlarged view in FIG. 9C, the ring gear 302 is provided with a hollow portion 302a and a discharge hole 302b communicating with the hollow portion 302a. The differential case 303 is provided with an insertion hole 303a communicating with the discharge hole 302b and having one end opened to the outside. The ring gear 302 is fixed to the pinion shaft 305 by inserting the fixing pin 304 into the insertion hole 303a.

  At this time, the discharge hole 302b and the insertion hole 303a of the ring gear 302 are closed together by the fixing pin 304. Therefore, the powder of metal or the like remaining inside the hollow portion 302a of the ring gear 302 is blocked by the fixing pin 304, so that this powder can be prevented from leaking to the outside.

  With the configuration as described above, according to the present embodiment, the following operational effects can be obtained.

According to the first and second embodiments, the three-dimensional additive manufacturing method has a cavity (cavity 13 and the like) and a discharge hole (discharge hole 11c and the like) for discharging the internal residue of the cavity. The first member (case body 2 and the like) is shaped, the internal residue is removed from the discharge hole of the first member, and the second member (extension housing 3 and the like) is closed so as to close the discharge hole of the first member. Since it is assembled, even if the internal residue that could not be removed is going to go out from the cavity of the first member, it will not leak out through the closed discharge hole. Therefore, it is possible to provide a method of manufacturing a structure that can prevent internal residues of the structure (such as the transmission 1) from leaking to the outside.

Further, according to the first reference example , the case main body 2 and the extension housing 3 are components of the transmission case of the transmission 1, and the discharge holes are formed in the mating surfaces 2 b and 3 b of the case main body 2 and the extension housing 3. Since 11c, 11c is obstruct | occluded, it can prevent that the internal residue of the case main-body part 2 and the extension housing 3 leaks outside via the discharge holes 11c, 11c.

Further, according to the first embodiment, the discharge holes 102b and 103b are closed by welding the output gear 102 and the parking gear 103 to each other, so that the internal residues of the output gear 102 and the parking gear 103 are discharged to the discharge holes 102b and 103b. It is possible to prevent leakage to the outside through the. Similarly, according to the second embodiment, the discharge holes 203b and 204b are closed by welding the carrier 203 and the gear 204 to each other, so that the internal residue of the carrier 203 and the gear 204 is passed through the discharge holes 203b and 204b. It is possible to prevent leakage to the outside.

Further, according to the second reference example , the discharge hole 302b is closed by inserting the fixing pin 304 into the insertion hole 303a communicating with the discharge hole 302b provided in the ring gear 302, so that the internal residue of the ring gear 302 is discharged. It is possible to prevent leakage to the outside through the hole 302b and the insertion hole 303a.

Further, according to the first reference example , since the transmission 1 houses therein a hydraulic control valve mechanism for controlling the working fluid, internal residues such as powder are mixed in the working fluid such as oil. There is no fear.

Further, according to the first reference example , since the working fluid control mechanism is a hydraulic control valve mechanism, the internal residue of the transmission 1 leaks out and enters the working fluid, and the hydraulic control valve to which the working fluid is supplied It is possible to prevent the mechanism or the like from malfunctioning due to the biting of the internal residue.

  The present invention is not limited to the illustrated embodiments, and various improvements and design changes can be made without departing from the spirit of the present invention.

  For example, in this embodiment, the internal structure is common to all the bone parts constituting the skeleton part, but the present invention is not limited to this, and the internal structure may be different depending on the location of the bone part. .

  For example, in the present embodiment, the skeleton part and the wall surface part of the case are integrally formed by the three-dimensional additive manufacturing method, but the present invention is not limited to this. For example, only the skeleton part of the case is three-dimensional additive manufacturing method. The case is formed by injection molding using a resin material such as a thermoplastic resin or die casting using a metal material such as aluminum by inserting the skeleton portion formed thereafter into a predetermined position of the mold and molding the case. It is also possible to integrally form the skeleton part and the wall surface part.

  As described above, according to the present invention, it is possible to provide a method for manufacturing a structure that can prevent the internal residue of the structure from leaking to the outside. There is a possibility of being suitably used in the vehicle manufacturing industry field, such as when manufacturing a case of a structure.

1 Transmission (structure)
2 Case body (first member)
2b Mating surface 3 Extension housing (second member)
3b Mating surface 11c Discharge hole 13 Cavity 303a Insertion hole

Claims (2)

A method of manufacturing a structure having a first member and a second member,
A first modeling step of modeling the first member having a cavity and a discharge hole for discharging the internal residue of the cavity by a three-dimensional additive manufacturing method;
A first removal step of removing the internal residue from the discharge hole of the first member;
A second modeling step of modeling the second member having a cavity and a discharge hole for discharging the internal residue of the cavity by a three-dimensional additive manufacturing method;
A second removal step of removing the internal residue from the discharge hole of the second member;
Assembling step of assembling the first member and the second member so that the discharge hole of the first member is closed by the second member and the discharge hole of the second member is closed by the first member . And a method for manufacturing the structure. A method of manufacturing a structure having a first member and a second member,
A first modeling step of modeling the first member having a cavity and a discharge hole for discharging the internal residue of the cavity by a three-dimensional additive manufacturing method;
A first removal step of removing the internal residue from the discharge hole of the first member;
A second modeling step of modeling the second member having a cavity and a discharge hole for discharging the internal residue of the cavity by a three-dimensional additive manufacturing method;
A second removal step of removing the internal residue from the discharge hole of the second member;
An assembling step of assembling the first member and the second member so that the discharge hole of the first member and the discharge hole of the second member are both closed by a welded portion.
A structure manufacturing method characterized by the above.