JP6934688B2 - Metal parts manufacturing method and metal parts manufacturing equipment - Google Patents

Description

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

Conventionally, for example, the insulator disclosed in Patent Document 1 is arranged between the lower surface of the floor pan and the muffler in the lower part of the vehicle for the purpose of soundproofing and heat shielding. The insulator is a panel-shaped first metal body made of an aluminum alloy material, a sheet-shaped sound absorbing and heat insulating body arranged on the floor pan side of the first metal body, and a floor pan side of the sound absorbing and heat insulating body. It is provided with a film-like second metal body made of an aluminum alloy material arranged in the above, and the outer peripheral portion of the first metal body is folded back, and the outer peripheral portion of the sound absorbing and heat insulating body and the second metal body are folded back at this folded portion. The first metal body, the sound absorbing and heat insulating body, and the second metal body are integrated by sandwiching the outer peripheral portion of the metal body at the same time.

By the way, in an 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 back the outer peripheral portion of the first metal body. There is a demand to integrate the first metal body and the second metal body by doing so, and as the joining method, it is possible to apply the ultrasonic joining method, which is less likely to be affected by thermal strain on the appearance of the insulator after completion. Conceivable.

Special Table 2006-591710

However, since the ultrasonic joining method applies minute vibrations to the joining part at the time of joining, ultrasonic waves are applied to a portion of the metal body to be joined where there is a highly rigid part such as around a reference hole for positioning with respect to a jig. When vibration propagates, cracks and cracks may occur due to repeated load applied to the location.

The present invention has been made in view of these points, and an object of the present invention is to obtain a metal part without cracks or cracks by integrating two panel-shaped 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 vibrate.

That is, in the first invention, a jig main body installed on the floor, a plurality of reference pins arranged at different positions, and each reference pin are oscillatingly attached to the jig main body and elastic made of a rubber material. A step of preparing a jig different from the panel-shaped metal body to be processed, which has a pin mounting means composed of a body, and an ultrasonic bonding means capable of ultrasonic bonding, and the panel-shaped metal body. a is, the two panel-shaped metal body having a plurality of fitting holes are formed corresponding to the respective reference pins each, as each reference pin is fitted into each fitting Goana of the respective metal bodies A step of placing each of the metal bodies on the jig body in order, and a step of integrally obtaining a metal part by forming a joint portion on the overlapping portion of each of the metal bodies by the ultrasonic bonding means. It is characterized by including.

Further, the present invention includes a jig main body installed on a floor, a jig having a plurality of reference pins, and an ultrasonic bonding means arranged on the side of the jig and capable of ultrasonic bonding, each of which is provided. fitted to a plurality of fitting holes are formed and another two panel-shaped metal body with said jig corresponding to the respective reference pins, each of the reference pins in each fitting Goana of the respective metal bodies By forming a joint portion on the overlapping portion of each metal body by the ultrasonic bonding means in a state where the metal bodies are placed on the jig body in order so as to be integrally obtained, the metal parts are integrally obtained. The following solutions were taken for the configured metal parts manufacturing equipment.

That is, in the second invention, the jig main body includes pin mounting means for attaching the reference pins to the jig main body so as to be vibrable, and the reference pins are arranged at different positions. The pin mounting means is characterized by being an elastic body made of a rubber material.

In the first and second inventions, each metal body is placed on the jig body in order so that each reference pin fits into each fitting hole of each metal body. When ultrasonic bonding is performed on the overlapping portions of the metal bodies by ultrasonic bonding means, minute vibrations propagate over the entire area of each metal body, and the pin mounting means vibrate in accordance with the vibrations. Therefore, the two metal bodies placed on the jig vibrate in synchronization with the ultrasonic vibration, and it becomes difficult to repeatedly apply a load to the highly rigid parts of the two metal bodies, resulting in cracks and cracks. Occurrence can be suppressed.

Further, since the reference pin vibrates in response to ultrasonic vibration with a simple structure, it is possible to manufacture a metal part by ultrasonic bonding with a low-cost device.

It is a perspective view of the insulator manufactured by the manufacturing apparatus which concerns on embodiment of this invention. FIG. 5 is a cross-sectional view taken along the line II-II of FIG. It is the schematic of the manufacturing apparatus which concerns on embodiment of this invention, and shows the state which two metal bodies and a sound absorbing heat insulating body are placed on the jig used when manufacturing an insulator. FIG. 3 is an enlarged view of part IV 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 essentially merely an example.

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 the floor pan F1 of the vehicle for the purpose of heat insulation and soundproofing against heat and noise generated from exhaust system parts and drive system parts, and is an insulator manufacturing apparatus shown in FIGS. 3 and 4. It is manufactured by 10 (metal parts manufacturing equipment).

As shown in FIGS. 1 and 2, the insulator 1 is formed on a first metal body 2 made of a panel-shaped aluminum alloy material extending in the front-rear direction of the vehicle and a panel surface on the floor pan F1 side of the first metal body 2. A sheet-shaped glass wool material 3 (sound absorbing and heat insulating body) arranged along the sheet-shaped glass wool material 3 and a second metal body 4 made of a panel-shaped aluminum alloy material provided on the floor pan F1 side of the glass wool material 3 are provided. The second metal body 4 is assembled to the first metal body 2 so as to cover the glass wool material 3. The plate thicknesses of the first and second metal bodies 2 and 4 in FIGS. 1 to 4 are 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 1000 to 3000 series, and is a horizontal surface portion 21 extending in the front-rear direction of the vehicle. And a pair of inclined surface portions 22 that incline so as to be gradually positioned downward as the horizontal surface portion 21 approaches both ends in the vehicle width direction from both side portions in the vehicle width direction.

On each of the inclined surface portions 22, a pair of circular first seat surface portions 22a are formed in the front-rear direction of the vehicle at predetermined intervals in a plan view in which the overhanging surface projects upward and the overhanging surface extends horizontally. A first fitting hole 22b is formed through the center of the seat surface portion 22a.

A polymerization portion 2b that overlaps with the second metal body 4 when the second metal body 4 is assembled is provided on a portion of the first metal body 2 outside the four first bearing surface portions 22a, and the first metal body 2 is provided. A large number of through holes 2c are formed in the portion of the metal body 2 surrounded by the four first seating surfaces 22a.

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 1000 to 3000 series, and is a horizontal panel portion extending in the front-rear direction of the vehicle. The horizontal panel portion 41 includes a pair of inclined panel portions 42 that are inclined so as to be gradually positioned downward as they approach both ends in the vehicle width direction from both side portions in the vehicle width direction of the horizontal panel portion 41.

On each of the inclined panel portions 42, a second seat surface portion 42a, which has a circular shape in a plan view and projects upward and the overhanging surface extends horizontally, corresponds to each first seat surface portion 22a of the first metal body 2. As described above, a pair is formed, and a second fitting hole 42b is formed through the center of each of the second seat surface portions 42a.

A polymerization portion 4b that overlaps with the polymerization portion 2b when assembled to the first metal body 2 is provided on a portion of the second metal body 4 outside the four second bearing surface portions 42a, and the second metal body In the portion surrounded by the four second seating surfaces 42a in No. 4, a space forming portion 4a is formed so as to project upward in a stepped manner with respect to the overlapping portion 4b.

Then, when the second metal body 4 is assembled to the first metal body 2, the polymerized portion 2b of the first metal body 2 and the polymerized portion 4b of the second metal body 4 overlap each other, and the first metal body 4 is overlapped with each other. A storage space layer S1 for accommodating the glass wool material 3 is formed between the space forming portion 4a in the second metal body 4 and the space forming portion 4a.

Further, between the polymerized portion 2b of the first metal body 2 and the polymerized portion 4b of the second metal body 4, the polymerized portion 2b of the first metal body 2 and the polymerized portion 4b of the second metal body 4 A plurality of solid-state bonding portions W1 formed by ultrasonic bonding are intermittently formed along the outer peripheral portions of the first and second metal bodies 2 and 4, and are formed by the solid-state bonding portions W1. , The first metal body 2 and the second metal body 4 are integrated.

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

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 main 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 forming a rectangular apex in a plan view, and the two support frames 53 on the side closer to the ultrasonic bonding machine 6 are on the side farther 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 portion of each of the support frames 53.

As shown in FIG. 4, the positioning unit 54 includes a metal unit main body 55 having a housing recess 55a that opens diagonally upward on the ultrasonic bonding machine 6 side, and is substantially half of the bottom surface side of the housing recess 55a. An elastic body 56 (pin positioning means) made of a ring-shaped hard rubber material is fitted therein.

Further, the accommodating recess 55a accommodates a reference pin 57 including a disk-shaped head 57a and a shaft portion 57b continuous with the head portion 57a, and the head portion 57a is in a posture in which the shaft portion 57b faces upward. Fits inward of the elastic body 56, and the shaft portion 57b protrudes outward from the opening portion of the accommodating recess 55a.

That is, the elastic body 56 is adapted to vibrate the reference pin 57 and attach it to the jig body 51.

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

Then, the second metal body 4 is fitted so that the reference pins 57 fit into the second fitting holes 42b in a posture in which the side to be assembled to the first metal body 2 in the second metal body 4 faces upward. The glass wool material 3 is placed on the space forming portion 4a of the second metal body 4 while being placed on the jig main body 51, and the side of the first metal body 2 to which the second metal body 4 is assembled is arranged. 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 posture, the first metal body 2 is formed. The first and second metal bodies 2 and 4 are positioned in a state where the polymerized portion 2b and the polymerized portion 4b of the second metal body 4 are overlapped with each other.

As shown in FIG. 3, the ultrasonic bonding machine 6 includes a pedestal portion 61 capable of supporting both overlapping portions 2b and 4b of the first and second metal bodies 2 and 4 positioned on the jig 5, and the pedestal portion 61. Pressurization that is arranged above the pedestal portion 61 and capable of ultrasonic vibration, and the vibrating portion 62 is lowered to sandwich the two overlapping portions 2b and 4b between the pedestal portion 61 and pressurize the vibration portion 62. The bipolymerized portion 62 is provided with a portion 63, and the vibrating portion 62 performs ultrasonic vibration while the pressurizing portion 63 pressurizes the both superposed portions 2b and 4b with the pedestal portion 61. A solid-state bonding portion W1 is formed between 2b and 4b.

Then, the ultrasonic bonding machine 6 moves the jig body 51 by a moving means (not shown), and the first and second metal bodies 2 and 4 are both superposed 2b, positioned by the jig body 51. By intermittently bonding 4b along the outer peripheral portions of the first and second metal bodies 2 and 4, the first and second metal bodies 2 and 4 are integrated to obtain the insulator 1.

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 facing upward. The second metal body 4 is placed on the jig body 51.

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

Next, the first metal body 2 is fitted with the reference pins 57 in the first fitting holes 22b in a posture in which the side to which the second metal body 4 is assembled is facing downward. Is placed on the jig body 51. Then, the polymerized portion 2b of the first metal body 2 and the polymerized portion 4b of the second metal body 4 overlap each other, and between the first metal body 2 and the space forming portion 4a of the second metal body 4. The accommodating space layer S1 is formed, and the glass wool material 3 is accommodated in the accommodating space layer S1.

After that, while moving the jig body 51 by a moving means (not shown), the ultrasonic bonding machine 6 moves the overlapping portions 2b and 4b of the first and second metal bodies 2 and 4 positioned by the jig body 51. By intermittently ultrasonically bonding the first and second metal bodies 2 and 4 along the outer peripheral portions, the first and second metal bodies 2 and 4 are integrated to obtain the insulator 1.

The bonding conditions for ultrasonic bonding were vibration frequency: 20 kHz, amplitude of the vibration unit 62: 0.06 mm, and pressure applied by the pressurizing unit 63: 1.5 kN.

From the above, according to the embodiment of the present invention, when ultrasonic bonding is performed on the two polymerization portions 2b and 4b, minute vibrations propagate over the entire areas of the first and second metal bodies 2 and 4, but the vibrations At the same time, each of the elastic bodies 56 vibrates. Therefore, 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 is difficult to repeatedly apply a load to the portion, it is possible to suppress the occurrence of cracks and cracks in the first and second metal bodies 2 and 4.

Further, since each elastic body 56 is made of a hard rubber material, the reference pin 57 vibrates in response to ultrasonic vibration with a simple structure, and the manufacture of the insulator 1 by ultrasonic bonding is low cost. It 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 fitting holes 22b of the first and second metal bodies 2 and 4 are positioned. The configuration is such that each reference pin 57 is only fitted into the two fitting holes 42b, but the circumference of each first fitting hole 22b of the first metal body 2 is pressed by the claw member of the clamp mechanism. May be good.

Further, in the embodiment of the present invention, the elastic body 56 is made of a hard rubber material, but the present invention is not limited to this, and for example, it may be made of a foam material.

Further, in each of the joinings applied to the overlapping portions 2b and 4b of the first and second metal bodies 2 and 4, the first and second metal bodies 2 and 4 are transferred to different jigs 5 in the middle of each joining. After mounting, the remaining joints may be performed.

Further, each of the joints applied to the overlapping portions 2b and 4b of the first and second metal bodies 2 and 4 is a mechanism that can change the positioning posture provided in the jig 5 in the middle of each joint, or The industrial robot may change the postures of the first and second metal bodies 2 and 4 by changing the inclination of the jig 5 itself, and then perform the remaining joinings.

Further, in the embodiment of the present invention, the insulator 1 is manufactured from the first metal body 2, the glass wool material 3 and the second metal body 4 by the manufacturing method of the present invention, but the manufacturing method of the present invention is not limited to this. It is also possible to obtain other metal parts by integrating two metal bodies forming 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 in a vehicle from two panel-shaped 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 mounting means)
57 Reference pin W1 joint

Claims (2)

A jig body installed on the floor, a plurality of reference pins arranged at different positions, and a pin mounting means made of an elastic body made of a rubber material and oscillating each reference pin to the jig body. A process of preparing a jig different from the panel-shaped metal body to be processed and an ultrasonic bonding means capable of ultrasonic bonding.
A the panel-shaped metal body, the two panel-shaped metal body having a plurality of fitting holes are formed corresponding to the respective reference pins each, each reference pin is in each fitting Goana of the respective metal bodies The process of placing each of the above metal bodies on the above jig body in order so as to be fitted, and
A method for manufacturing a metal part, which comprises a step of integrally obtaining a metal part by forming a joint portion by the ultrasonic bonding means in an overlapping portion of each of the metal bodies. A jig body installed on the floor, a jig with multiple reference pins, and
It is provided on the side of the jig and is provided with an ultrasonic bonding means capable of ultrasonic bonding.
Each multiple fitting holes are formed and another two panel-shaped metal body with said jig corresponding to the respective reference pins, each reference pin is fitted into each fitting Goana of the respective metal bodies Metal parts are integrally obtained by forming a joint portion with the ultrasonic bonding means on the overlapping portion of the metal bodies in a state where the metal bodies are sequentially placed on the jig body so as to match. It is a metal parts manufacturing equipment configured as
The jig body is provided with pin mounting means for attaching each reference pin to the jig body so as to be vibrable.
Each of the above reference pins is located at a different position.
The pin mounting means is a metal parts manufacturing apparatus characterized in that it is an elastic body made of a rubber material.

Images