JP2017192951A - Manufacturing method of aluminum molded article - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of an aluminum molded article which can securely suppress wrinkles on a joint part of a flange part protruded to an inside of a bending direction of the aluminum molded article having a main body part and the flange part.SOLUTION: A roof side rail 1 as an aluminum molded article is formed of an aluminum shape member 12 including a long main body part 2 and a lower flange part 3 integrally formed with the main body part 2 along a longitudinal direction of the main body part 2. A manufacturing method of the roof side rail includes: a bending process of bending the aluminum shape member 12 so that the lower flange part 3 is on an inner side than the main body part 2; and a projecting process of forming a projection part 7 having a flat part 10 by projecting a region including at least one joint part 10 joined to a joining object of the lower flange part 3 to a surface orthogonal direction W orthogonal to a surface of the lower flange part 3.SELECTED DRAWING: Figure 2

Description

  The present invention relates to a method for manufacturing an aluminum molded product constituting a frame of an automobile.

  In recent years, in order to reduce the weight of automobiles and the like, techniques for manufacturing parts such as frames using aluminum alloys have been developed. In particular, aluminum extrusions are formed by extruding aluminum alloy materials, and can be easily formed into a closed cross-section structure, reducing the number of welding points and parts. And it is advantageous in that high rigidity is obtained. Therefore, recently, aluminum extruded profiles have been applied to frame components such as roof side rails extending in the front-rear direction on both sides of the vehicle body.

  The roof side rail is a hollow part made of an aluminum alloy that is continuously arranged along the side surfaces of the roof and the front window of the automobile and is curved so as to protrude upward. The roof side rail has a closed cross-sectional structure, and has a main body portion that is curved upward and extends in the longitudinal direction, and a flange portion that protrudes from the outer surface of the main body portion and extends in the longitudinal direction. The flange portion is provided on the outer surface of the main body portion in order to join a member such as an outer side panel of an automobile to the flange portion by spot welding or the like. The main body portion and the flange portion are integrally formed by extruding an aluminum alloy. A curved roof side rail is manufactured by bending the aluminum profile in which the main body and the flange are integrally formed.

  Here, the flange portion of the roof side rail may protrude downward from the outer surface of the main body, that is, inward in the bending direction of the main body. In this way, when bending the aluminum profile in which the main body and the flange protruding inward in the bending direction are integrally formed, the lower end of the flange is buckled and wrinkles occur in the flange. There is a fear.

  In a state where wrinkles are generated in the flange portion, it is difficult to bond the outer side panel to the flange portion and join them by spot welding or the like. Thus, when adhesiveness falls, it will become difficult to ensure the sealing performance and joining strength in the junction part of a flange part.

  Then, the bending method of patent document 1 is known as a method for suppressing the wrinkle in the junction part of a flange part in the case of the bending process in such a roof side rail.

  In the bending method of Patent Document 1, before bending, in the flange portion of the roof side rail, a portion that is likely to be deformed during bending at a position away from a joint portion to be joined to the outer side panel or the like ( That is, an easily deformable portion) is provided in advance. The easily deformable portion is formed by providing a plurality of grooves in the flange portion or by deforming the flange portion into a wave shape. By generating wrinkles locally in the easily deformable portion of the flange portion during bending, the occurrence of wrinkles in the joint portion of the flange portion is suppressed and the flatness of the joint portion is ensured.

JP 7-328735 A

  In the bending method of Patent Document 1 described above, it is difficult to predict in which region the wrinkle is generated in the flange portion during bending, and the possibility that wrinkles occur in places other than the easily deformable portion is not possible. It still remains. Therefore, it is difficult to reliably suppress wrinkles at the joint portion of the flange portion. In particular, when there are a plurality of joint portions in the flange portion over a wide range, it is more difficult to suppress wrinkles in all the joint portions.

  The present invention has been made in view of the circumstances as described above, and reliably suppresses wrinkles at the joint portion of the flange portion protruding inward in the bending direction in an aluminum molded product having a main body portion and a flange portion. An object of the present invention is to provide a method for producing an aluminum molded product.

  In order to solve the above problems, the present invention provides an aluminum shape including a long main body and a flange formed integrally with the main body along the longitudinal direction of the main body. A method of manufacturing an aluminum molded article made of a material, a bending step of bending the aluminum shaped material so that the flange portion is on the inner side of the main body portion; A projecting step of projecting a region including at least one joined part to be joined in a direction perpendicular to the plane perpendicular to the surface of the flange part to form a projecting part having a flat part. .

When an aluminum shaped material with a flange formed along the longitudinal direction of the long main body is bent so that the flange is inside the bending direction of the main body, the flange is compressed. When the stress is applied, a surplus portion is generated in the flange portion, and as a result, wrinkles and dents are generated in the flange portion. In the present invention, in the projecting step, by partially projecting a region including at least one joining part to be joined to the joining object in the flange part in the direction orthogonal to the surface of the flange part, that is, in the surface orthogonal direction An overhang having a flat portion is formed. This makes it possible to absorb the meat-odd flange portion which occurs when the bending process by the projecting portion, wrinkles definitive in a region including the bonding portion is reliably prevented. As a result, the flatness of the region can be obtained, so that it is possible to ensure a sufficient quality of the joint portion.

  The aluminum molded product is a part constituting a frame of an automobile, and the joining object comprises an outer surface of the automobile, and has an outer panel joined to a surface of the flange portion facing the outside of the automobile. Is preferred.

  For parts that make up automobile frames (for example, roof side rails and side members), the outer surface of the automobile is used to ensure the quality of the joints and, depending on the parts, to prevent water from entering the frame of the closed cross-section structure. It is important to join the plate parts such as the outer panel, the inner panel, or the reinforcing member and the flange portions of the parts constituting the frame in close contact with each other. In the above manufacturing method, in the overhanging step, the overhanging portion having a flat portion projecting in the direction perpendicular to the plane is formed in the region including the bonding portion in the flange portion, so that wrinkles in the bonding portion are reliably suppressed. For this reason, the outer panel can be brought into close contact with the joint portion of the flange portion, and the joint strength at the joint portion can be ensured. Further, since the joint portion can be flattened, it is possible to ensure a sufficient sealing performance even for parts that require watertightness.

  It is preferable that the part is a roof side rail that is continuously arranged along a side surface of a roof and a front window of the automobile in the automobile frame.

  Of the parts constituting the automobile frame, the roof side rail has a curved main body portion and a flange portion on the inner side in the bending direction of the main body portion in order to secure a shape that can be arranged along the side surfaces of the roof and the front window. is necessary. In addition, the roof side rail is a component that is coupled to the outer panel that forms the outer surface of the automobile, and has a role of handling a collision load at the time of frontal collision or rollover between vehicles. In order to ensure the strength for that purpose, it is important to ensure the bonding quality between the roof side rail and the outer panel, and suppressing wrinkles of the flange portion in the roof side rail is a major issue. Thus, by applying the aluminum molded product to the roof side rail, sufficient joining quality can be ensured.

  In the overhanging step, the region of the flange portion is orthogonal to the plane so that the length of the front end of the flange portion extending in the longitudinal direction is equal to or longer than the length of the aluminum profile in the longitudinal direction before the bending step. It is preferable to project in the direction.

  Thus, by setting the amount of protrusion of the flange portion in the overhanging step, it is possible to reliably absorb the surplus due to wrinkling of the flange portion that occurs during the bending step. In other words, during the bending process, there is a surplus at the tip of the flange portion located inside the bending direction, but the flange portion is projected so that the length of the tip of the flange portion is equal to or greater than the length of the aluminum profile before the bending process. By performing the process, it is possible to absorb the surplus portion of the flange portion with the overhang portion, suppress wrinkles in the flange portion, and ensure the flatness of the joined portion.

  In the projecting step, it is preferable that the flat portion is formed so as to continuously extend in the longitudinal direction of the main body so that the flat portion includes a plurality of the joint portions. Thereby, it is possible to obtain a wide range of flat regions including a plurality of joint portions, and the work of joining the joining object to the joint portions becomes easy.

  Moreover, it is preferable to form the shape change part extended in the said surface orthogonal | vertical direction in the said overhanging process in the position which continues to the edge part of the said longitudinal direction in the said flat part. In this configuration, even if a wide flat portion including a plurality of joint portions is formed on the flange portion, wrinkles generated in the wide range can be absorbed by the shape change portion.

  In the projecting step, it is preferable to perform plastic working on the flange portion so that the flange portion projects in one direction parallel to the plane orthogonal direction. Thereby, it is possible to easily form the overhang portion by pressing from one side.

  In the case where the bending step is a step of bending the aluminum shape member by pressing a bending die against the aluminum shape material, the bending die corresponds to the projecting portion at a portion contacting the flange portion. In the bending process, bending the aluminum shaped material in a state where the portion having the concave portion in the bending mold is pressed against one surface of the flange portion, and in the projecting step, In the state in which the portion having the concave portion in the bending die is pressed against one surface of the flange portion, the pressing die having the convex portion corresponding to the concave portion is pressed against the other surface of the flange portion. A protruding portion may be formed. In this case, since the overhanging process can be performed using the bending mold used in the bending process, it is possible to reduce the working time of the overhanging process and reduce the cost of creating the mold for the bending process and the overhanging process. Is possible. Furthermore, it is possible to shorten the time for handling the aluminum profile when shifting from the bending process to the projecting process.

  The aluminum profile is preferably formed by extrusion so that the main body has a closed cross-sectional structure. Thereby, it is possible to easily form an aluminum profile in which the main body portion and the flange portion having a closed cross-sectional structure are integrally formed.

  As described above, according to the method for manufacturing an aluminum molded product of the present invention, wrinkles in the joint portion of the flange portion protruding inward in the bending direction are reliably suppressed in the aluminum molded product having the main body portion and the flange portion. can do.

It is an external appearance perspective view of the frame | frame of the motor vehicle which has the roof side rail manufactured with the manufacturing method of the aluminum molded product of this invention. It is a perspective view of the roof side rail of FIG. It is the III-III sectional view taken on the line of FIG. It is the IV-IV sectional view taken on the line of FIG. FIG. 3 is a view of the roof side rail of FIG. 2 as viewed from the direction of an arrow P. FIG. 3 is an explanatory cross-sectional view showing a state in which an outer side panel and an inner side panel are joined to the roof side rail of FIG. 2. FIG. 3 is an explanatory perspective view illustrating a state in which an outer side panel and an inner side panel are joined to the roof side rail of FIG. 2. It is a perspective view of the aluminum shape material of the roof side rail before a bending process in the manufacturing method of the aluminum molded product of this invention. It is process explanatory drawing which shows the bending process which bends an aluminum shape material in the manufacturing method of the aluminum molded article of this invention. It is explanatory drawing which shows the method of push-through bending as an example of the method of bending an aluminum shape material. It is explanatory drawing which shows the method of the tension bending as another example of the method of bending an aluminum shape material. FIG. 12 is a sectional view taken along line XII-XII in the vicinity of the bending die in FIG. 11. In the manufacturing method of the aluminum molded product of this invention, it is process explanatory drawing which shows the overhang | projection process which plastically processes a lower flange part so that the overhang | projection part which has a flat part in a lower flange part may be formed. As a modification of the method for manufacturing an aluminum molded product according to the present invention, a roof side rail in which a plastic working is applied to a lower flange portion so as to form an overhang portion having a plurality of flat portions is manufactured. It is a perspective explanatory view showing the state where the outer side panel and the inner side panel are joined to the part.

  Hereinafter, embodiments of the method for producing an aluminum molded product of the present invention will be described in more detail with reference to the drawings.

  As an example of an aluminum molded product manufactured by the manufacturing method of the present invention, a roof side rail 1 which is a component constituting the automobile frame 100 shown in FIG. 1 will be described as an example.

  The roof side rail 1 is an aluminum hollow extruded member that constitutes pillars (so-called A pillars) that are continuously arranged along the sides of the roof and front window of the automobile frame 100.

  As shown in FIGS. 2 to 5, the roof side rail 1 includes a long main body 2 that is curved so as to be convex upward, and an inner surface of the main body 2 in the bending direction from the outer surface of the main body 2 ( A lower flange portion 3 projecting downward (lower side in FIGS. 2 to 4), and a side flange portion 4 projecting laterally (width direction X of the frame 100 shown in FIGS. 1 and 3) from the outer surface of the main body 2. Have

  The lower flange portion 3 and the side flange portion 4 are joined at the end portions such as the outer side panel 21 and the inner side panel 22 shown in FIGS.

  The main body 2 has a closed cross-sectional structure. That is, the cross section orthogonal to the longitudinal direction of the main body 2 has a closed shape. For example, as shown in FIGS. 2 to 3, the main body 2 includes a cylindrical portion 5 and a reinforcing portion 6 that extends up and down inside the cylindrical portion 5. The internal structure of the main body 2 is not limited in the present invention. The shape of the closed section of the main body 2, the presence or absence of the reinforcing portion 6, the thickness of each part of the main body 2, etc. It is designed appropriately according to design conditions such as synthesis and strength. The main body 2 shown in FIGS. 1 and 2 is curved over its entire length. In addition, the main-body part 2 should just be curving at least one part.

  The lower flange portion 3 protrudes from the outer surface of the main body portion 2 to the inside of the bending direction of the main body portion 2 (lower side in FIGS. 2 to 4) and is continuously curved in the longitudinal direction of the main body portion 2. The lower flange portion 3 corresponds to the flange portion of the present invention. In the present embodiment, the roof side rail 1 has the lower flange portion 3 and the side flange portion 4, but the side flange portion 4 is not limited to be formed in the manufacturing method of the present invention.

  The lower flange portion 3 includes an overhang portion 7 and end portions 8 located on both sides in the longitudinal direction of the overhang portion 7.

  The overhang portion 7 is formed by an overhang process. Specifically, as illustrated in FIGS. 2 to 5, the overhanging portion 7 is joined to a joining target such as the outer side panel 21 and the inner side panel 22 (see FIGS. 6 to 7) in the lower flange portion 3. The lower flange portion 3 is formed by subjecting the lower flange portion 3 to plastic working so that a region including the plurality of joint portions 10 projects in a plane orthogonal direction W that is a direction orthogonal to the surface of the lower flange portion 3. The joining portion 10 is a spot-like or line-like portion to be joined to a joining target such as the outer side panel 21 by spot welding or the like in the lower flange portion 3, and at least one joining portion 10 is sufficient.

  The overhang portion 7 includes a flat portion 7a and a shape changing portion 7b continuous with the flat portion 7a.

  The flat portion 7a is a portion obtained by flattening the region including the joint portion 10. The flat portion 7 a of this embodiment extends continuously in the longitudinal direction of the main body 2 so as to include a plurality of joint portions 10. In the present embodiment, the plurality of joint portions 10 are arranged side by side along the longitudinal direction of the main body 2.

  The shape changing portion 7b is a portion extending in the plane orthogonal direction W of the lower flange portion 3 continuously to the flat portion 7a around the flat portion 7a. The shape change part 7b of this embodiment is formed in the position which follows the edge part of the longitudinal direction in the flat part 7a. Accordingly, the shape changing portion 7b extends in the plane orthogonal direction W, and connects the flat portion 7a and the end portion 8 located at the longitudinal end portion of the flat portion 7a.

  The roof side rail 1 configured as described above is covered with the outer side panel 21 and the inner side panel 22 as shown in FIGS. 21 and 22 are joined. Specifically, the lower end portions of the outer side panel 21 and the inner side panel 22 sandwich the flat portion 7a of the projecting portion 7 of the lower flange portion 3 from both sides, and in this state, the flat portion 7a and the panels 21 on both sides, 22 are joined at the joint 10 by spot welding or the like. Similarly, the upper end portions of the outer side panel 21 and the inner side panel 22 are also joined to the side flange portion 4 by spot welding or the like. Although not shown, the side flange portion 4 and the outer side panel 21 are joined together with the end portion of the roof panel interposed between the side flange portion 4 and the outer side panel 21.

  In addition, in the position 11 of the edge part of the roof side rail 1 shown by FIG. 7, the said roof side rail 1 and the pillar 101 (what is called B pillar) extended in the up-down direction of the flame | frame 100 are joined.

  The manufacturing method of the following roof side rail 1 is demonstrated.

  The manufacturing method of the roof side rail 1 according to the present embodiment includes a preparation step of preparing a linear aluminum shape member 12, a bending step of bending the aluminum shape member 12, and a lower flange portion 3 as follows. A projecting step of performing plastic working on the lower flange portion 3 so that the joint portion 10 projects.

  First, in the preparation step, an aluminum shaped member 12 shown in FIG. 8 is prepared. The aluminum profile 12 is an aluminum extruded profile that extends linearly. The aluminum shaped member 12 has a shape before the roof side rail 1 is bent, and specifically, a body portion 2, a lower flange portion 3, and a side flange portion 4 that extend linearly, respectively. including. The aluminum profile 12 is configured by integrally forming the main body 2, the lower flange 3, and the side flange 4 from aluminum or an aluminum alloy.

  In this preparation step, specifically, the aluminum shaped member 12 is extruded so that a cross section perpendicular to the longitudinal direction of the main body 2 has a closed cross-sectional structure. Thereby, the aluminum profile 12 in which the main body 2 having a closed cross-sectional structure made of aluminum or an aluminum alloy, and the lower flange 3 and the side flange 4 projecting from the outer surface of the main body 2 are easily formed. It is possible to form. Since the main body 2 has a closed cross-sectional structure, the bending rigidity of the main body 2 can be changed by changing the cross-sectional shape thereof. By changing the bending rigidity of the main body 2, it is possible to reduce wrinkles of the lower flange portion 3 that occur during the following bending process.

  In the bending step, as shown in FIG. 9, the bent body portion 2 and the lower flange portion 3 are bent by bending the aluminum shaped member 12 so that the lower flange portion 3 is located inside the bending portion with respect to the main body portion 2. The roof side rail 1 (refer FIG. 2) which has is formed.

  Here, as a method for bending the aluminum shaped member 12, a conventionally known bending method of an aluminum member, for example, rotary pull bending, compression bending, roll bending, press bending, tensile bending, And methods such as push-through bending are used.

  In the case of automobile frames such as the roof side rail 1, three-dimensional bending using tension bending or push-through bending is actually used. The three-dimensional bending process is a process of bending a material in a plurality of bending directions. For example, after bending the material in a first direction (for example, a downward direction), a second direction different from the first direction ( For example, a process of bending in the lateral direction).

In the case of push-through bending, as shown in FIG. 10, a processing apparatus 31 having a fixed-side bending die 32 and a movable-side bending die 33 is used. This push-through bending, by moving the movable side of the bending die 33 upward or downward or the like while pushing continuously aluminum profile 12 is an aluminum profile into two bending tools 32 and 33, an aluminum shape The material 12 can be bent. The bending dies 32 and 33 are formed with slits 32a and 33a through which the lower flange portion 3 of the aluminum profile 12 passes. In this push-through bending process, each of the bending dies 32 and 33 can be reduced in size, and the aluminum shaped member 12 can be bent to an arbitrary curvature radius by moving the bending dies 33 on the movable side. Therefore, mold costs and adjustment costs are relatively low.

  Further, in the case of tensile bending, as in the processing device 36 shown in FIGS. 11 to 12, both ends of the aluminum shaped member 12 are held by the jig 38 and a tensile force is applied to the aluminum shaped member 12. The bending die 37 is bent so as to press the aluminum profile 12 from below to above (that is, in the direction of arrow P). The tensile bending process is advantageous in that it is less likely to generate wrinkles and has better shape accuracy than the push-through bending process. Note that the bending die 37 shown in FIG. 12 is used as one of a pair of molds 37 and 39 for the overhanging process in the next overhanging step. The bending die 37 shown in FIG. 12 has a concave portion 37a corresponding to the overhanging portion 7 formed in the overhanging process at a portion that contacts the lower flange portion 3.

  After the bending process, an overhang process is performed. In the projecting step, the lower flange portion 3 is subjected to plastic working so that a region including at least one joining portion 10 to be joined to the joining target in the lower flange portion 3 projects in the surface orthogonal direction W of the lower flange portion 3. It is a process. Specifically, as shown in FIG. 13, a pair of molds, that is, the bending die 37 and the pressing die 39 are used.

  In the overhanging process, as shown in FIG. 13, the pressing die 39 having the convex portion 39a corresponding to the concave portion 37a is moved to the lower flange while the concave portion 37a of the bending die 37 is pressed against one surface of the lower flange portion 3. Press against the other surface of the part 3. At this time, the lower flange portion 3 is plastically deformed by fitting the concave portion 37a and the convex portion 39a, thereby forming the overhanging portion 7 projecting in the plane orthogonal direction W in the lower flange portion 3.

  In this projecting step, the flat portion 7a is formed so as to continuously extend in the longitudinal direction of the main body 2 so that the flat portion 7a includes the plurality of joint portions 10. At the same time, the shape changing portion 7b can be formed at a position where the shape changing portion 7b continues to the end portion in the longitudinal direction of the flat portion 7a.

  In the manufacturing method of the roof side rail 1 described above, in the bending process, a flange portion is formed on the aluminum shape member 12 in which the flange portion 3 is formed along the longitudinal direction of the long main body portion 2 of the aluminum shape member 12. When bending is performed so that 3 is inside in the bending direction with respect to the main body portion 2, a compression stress is applied to the flange portion 3, so that the flange portion 3 is left with a surplus, and as a result, the flange portion 3 is wrinkled. A dent occurs. Therefore, in the manufacturing method described above, a region including at least one joining portion 10 to be joined to the joining target in the flange portion 3 in the direction orthogonal to the surface of the flange portion 3 in the overhanging process, that is, the surface orthogonal direction W is partially included. The overhanging portion 7 having the flat portion 7a is formed by overhanging. As a result, the surplus portion of the flange portion 3 generated during the bending process can be absorbed by the overhang portion 7 (specifically, the shape changing portion 7b extending in the plane orthogonal direction W around the flat portion 7a). Thus, wrinkles in the region including the joint portion 10 are reliably suppressed. As a result, since the flatness of the region can be obtained, it is possible to ensure sufficient quality of the joint portion 10.

  In this overhanging process, the overhanging portion 7 is formed by constraining both surfaces of the bent flange portion 3 with a mold or the like, thereby providing a re-extrusion effect. The shape accuracy of the surface of the flange portion 3 is also improved.

  Further, in the above manufacturing method, it is not necessary to enlarge the curvature radius of the roof side rail 1 in order to suppress wrinkles of the lower flange portion 3 of the roof side rail 1, so that the vehicle body design is deteriorated and the visibility during driving is deteriorated. It is possible to reduce the risk of this.

  Moreover, in the above-described manufacturing method, even when the aluminum profile 12 is bent by tensile bending in the bending process, it is not necessary to apply an excessive tensile force to the aluminum profile 12 to suppress wrinkles of the lower flange portion 3. It is possible to suppress a decrease in the remaining elongation of the roof side rail 1 after manufacture. Therefore, it is possible to reduce the risk of the roof side rail 1 being broken at the time of a car collision. Further, since it is not necessary to apply an excessive tensile force to the aluminum shaped member 12 during the tensile bending process, it is possible to suppress the deformation of the cross section of the roof side rail 1 and the reduction of the wall thickness. As a result, it is possible to suppress a decrease in the bending strength and tensile strength of the roof side rail 1.

  Further, in the above manufacturing method, it is not necessary to divide the lower flange portion 3 in the longitudinal direction in order to suppress wrinkles of the lower flange portion 3, so that the decrease in bending strength and tensile strength of the roof side rail 1 due to the division is suppressed. Is possible.

  Further, in the above manufacturing method, it is not necessary to heat the bending die in the bending process in order to suppress wrinkles of the lower flange portion 3, so that it is not necessary to perform warm forming by using aluminum or an aluminum alloy as a material of the aluminum forming material 12. The risk of restricting material selection is reduced.

  The roof side rail 1 manufactured by the above-described manufacturing method is a component that constitutes the frame 100 of the automobile, and the object to be joined constitutes the outer surface of the automobile, and the lower flange portion 3 faces the outside of the automobile. An outer side panel 21 is provided as an outer panel to be joined. In parts such as the roof side rail 1 constituting the automobile frame 100, the outer surface of the automobile is used to ensure the quality of the joint portion 10 and, depending on the parts, to prevent water from entering the inside of the closed cross-section frame. It is important that the outer side panel 21, the inner side panel 22, or the plate material component such as the reinforcing material and the lower flange portion 3 of the component constituting the frame 100 are in close contact with each other and bonded together. In the manufacturing method described above, the bulging portion 7 having the flat portion 7a protruding in the plane orthogonal direction W is formed in the region including the bonding portion 10 in the lower flange portion 3 in the bulging process, whereby wrinkles in the bonding portion 10 are formed. Suppressed reliably. Therefore, the outer side panel 21 can be tightly bonded to the joint portion 10 of the lower flange portion 3, and the joint strength at the joint portion 10 can be ensured. In addition, since the joint portion 10 can be flattened, it is possible to ensure a sufficient sealing performance even for components that require watertightness.

  It should be noted that parts other than the roof side rail 1 among the parts constituting the automobile frame 100 that are joined to the outer panel, for example, parts such as the cross member 102 extending in the width direction X of the frame 100 are also located on the inner side in the bending direction. Since it has a flange part to which an outer panel etc. are joined, it is possible to show the above-mentioned operation effect.

  Among the components constituting the automobile frame 100, the roof side rail 1 as described above particularly has a curved main body portion 2 and the main body portion so as to secure a shape that can be arranged along the side surfaces of the roof and the front window. The lower flange portion 3 on the inner side in the bending direction 2 is required. Moreover, the roof side rail 1 is a part that is coupled to the outer side panel 21 that constitutes the outer side surface of the automobile and the inner side panel 22 that constitutes the inner side surface (see FIGS. 6 to 7). It plays a role in handling impact loads during rollover. In order to ensure the strength for that purpose, it is important to ensure the bonding quality between the roof side rail 1 and the outer and inner side panels 21 and 22, and suppressing wrinkles of the flange portion 3 in the roof side rail 1 is a major problem. It has become. Thus, by applying the aluminum molded product of the present invention to the roof side rail 1 described above, it is possible to ensure sufficient bonding quality.

  In the manufacturing method described above, the length of the tip 3d (see FIG. 2) extending in the longitudinal direction of the lower flange portion 3 in the projecting step is the length in the longitudinal direction of the aluminum member 12 (see FIG. 8) before the bending step. As described above, the lower flange portion 3 is subjected to plastic working so that the lower flange portion 3 projects in the direction perpendicular to the plane W. By setting the amount of extension of the lower flange part 3 in the extension process in this way, the surplus due to the wrinkles of the lower flange part 3 generated during the bending process is reduced in the extension part 7 (specifically, around the flat part 7a). It is possible to reliably absorb the shape change portion 7b) extending in the plane orthogonal direction W. That is, at the time of the bending process, a surplus occurs at the tip 3d of the lower flange portion 3 located inside the bending direction, but the length of the tip 3d of the lower flange portion 3 is the length of the aluminum profile 12 before the bending process. By performing the overhanging process so as to be more than that, it becomes possible to absorb the surplus portion of the lower flange portion 3 with the overhang portion 7 (specifically, the shape changing portion 7b), and the wrinkle in the lower flange portion 3 is absorbed. And the flatness of the joint portion 10 can be ensured.

  In the above manufacturing method, in the projecting step, the flat portion 7a of the lower flange portion 3 is formed so as to continuously extend in the longitudinal direction of the main body portion 2 in a region including the plurality of joint portions 10. Thereby, it is possible to obtain a wide range of flat regions including a plurality of joining portions 10, and the work of joining the joining object to the joining portions 10 is facilitated. In addition, the flat portion 7a of the lower flange portion 3 and the outer side panel 21 (and the inner side panel 22) can be brought into close contact with each other over a wide range, and both can be joined with good sealing properties.

  In the above manufacturing method, in the projecting step, the shape change portion 7b is formed at a position where the shape change portion 7b is continuous with the end portion in the longitudinal direction of the flat portion 7a. For this reason, even if a wide flat portion 7a including a plurality of joint portions 10 is formed in the lower flange portion 3 in the overhanging step, wrinkles generated in this wide range can be absorbed by the shape changing portion 7b. . Thereby, it becomes possible to increase the joint portion 10 while suppressing an increase in the shape changing portion 7b.

  In the projecting step, it is preferable to perform plastic working on the lower flange portion 3 so that the lower flange portion 3 projects in one direction parallel to the plane orthogonal direction W, as shown in FIG. Thereby, it is possible to perform plastic working on the lower flange portion 3 so that the lower flange portion 3 easily protrudes by pressing from one side.

  As shown in FIG. 14, a plurality of flat portions 7 a and 7 c that protrude in opposite directions in the plane orthogonal direction W in the lower flange portion 3 may be alternately formed. In this case, in the overhanging step, one mold is provided with a projection corresponding to the flat portion 7a, and the other mold is provided with a projection corresponding to the flat portion 7c, and these molds are used. Press molding is performed on the lower flange portion 3. Thereby, the some flat part 7a which protrudes in the vehicle inner side of the surface orthogonal direction W and the some flat part 7c which protrudes in the vehicle orthogonal direction W are formed. In this case, since the shape change part 7b extended between the some flat parts 7a and 7c increases, wrinkle absorption by the shape change part 7b is possible more easily.

  The plurality of flat portions 7a protruding to the vehicle inner side are joined to the inner side panel 22 by spot joining or the like at the joining portion 10b. The plurality of flat portions 7c protruding to the outside of the vehicle are joined to the outer side panel 21 by spot joining or the like at the joining portion 10a.

  In the case of the roof side rail 1 shown in FIG. 14, the lower part 22 a of the inner side panel 22 extends slightly in the downward direction and the direction extending in the plane orthogonal direction W to the vehicle outer side, and the lower part 22 a is connected to the outer side panel 21. By adopting such a close structure, it is possible to secure the sealing performance around the plurality of flat portions 7a and 7c, and to prevent water from entering the vehicle. In the vehicle body structure shown in FIG. 7 described above, a series of flat portions 7a continuously extending in the longitudinal direction of the roof side rail 1 are joined to the outer side panel 21 and the inner side panel 22 with good sealing performance. As in the vehicle body structure shown in FIG. 14, it is not necessary to extend the lower part 22a of the inner side panel 22 in order to ensure sealing performance, and it is possible to suppress an increase in vehicle body weight.

  11-13, in the manufacturing method of the said embodiment, when a bending process is a process of pressing the bending die 37 against the aluminum shape material 12, and bending the said aluminum shape material 12, it is bending. The mold 37 has a concave portion 37 a corresponding to the protruding portion 7 at a portion that abuts the lower flange portion 3. In the above bending process, the aluminum shaped member 12 is bent in a state where the portion having the concave portion 37 a in the bending die 37 is pressed against one surface of the lower flange portion 3. Then, in the projecting step, the pressing die 39 having the convex portion 39a corresponding to the concave portion 37a is attached to the lower flange portion 3 in a state where the portion having the concave portion 37a in the bending die 37 is pressed against one surface of the lower flange portion 3. The overhang portion 7 is formed by pressing against the other surface. In this case, since the overhanging process can also be performed using the bending die 37 used in the bending process, it is possible to reduce the working time of the overhanging process and to make the molds 37 and 39 for the bending process and the overhanging process. Can be reduced. Furthermore, it is possible to shorten the time for handling the aluminum profile 12 when shifting from the bending process to the projecting process.

  In place of the manufacturing method shown in FIGS. 11 to 13, after the aluminum shape member 12 is removed from the bending die 37 after the bending step, the lower flange portion 3 is sandwiched between a pair of molds dedicated to the overhang processing. An overhanging process may be performed. In this case, by appropriately setting the length of the pair of molds dedicated to the overhang processing, the flat portion 7a of the lower flange portion 3 is placed in the longitudinal direction of the main body portion 2 in the region including the plurality of joint portions 10 in the overhang process. It is possible to more easily achieve formation that extends continuously.

  In the manufacturing method of the present embodiment, as an example of a manufacturing method of an aluminum molded product, a manufacturing method of parts constituting the automobile frame 100 such as the roof side rail 1 and the cross member 102 shown in FIG. 1 will be described as an example. However, the present invention is not limited to this. The manufacturing method of the present invention includes a long main body portion that is at least partially curved, and a curved flange portion that protrudes from the outer surface of the main body portion inward in the bending direction of the main body portion and continues in the longitudinal direction of the main body portion. It can be widely applied to produce an aluminum molded product having

1 Roof side rail (aluminum molded product)
2 Body 3 Lower flange (flange)
DESCRIPTION OF SYMBOLS 7 Overhang | projection part 7a Flat part 7b Shape change part 10 Joining part 21 Outer side panel 22 Inner side panel 100 Automobile frame

Claims (9)

A method for producing an aluminum molded article comprising an aluminum shaped member including a long main body and a flange formed integrally with the main body along the longitudinal direction of the main body,
A bending step of bending the aluminum profile so that the flange portion is inside the body portion;
A projecting step of forming a projecting portion having a flat portion by projecting a region including at least one joining portion to be joined to the joining object in the flange portion in a plane orthogonal direction perpendicular to the surface of the flange portion. A method for producing an aluminum molded product, comprising: The aluminum molded product is a component constituting a frame of an automobile,
The joining object includes an outer panel that constitutes an outer surface of the automobile and is joined to a surface of the flange portion facing the outside of the automobile.
The manufacturing method of the aluminum molded article of Claim 1. The component is a roof side rail that is continuously disposed along the side of the automobile roof and the front window of the automobile frame.
The manufacturing method of the aluminum molded article of Claim 2. In the overhanging step, the region of the flange portion is orthogonal to the plane so that the length of the front end of the flange portion extending in the longitudinal direction is equal to or longer than the length of the aluminum profile in the longitudinal direction before the bending step. Overhang in the direction,
The manufacturing method of the aluminum molded article of any one of Claims 1-3. In the overhanging step, the flat portion is formed so as to continuously extend in the longitudinal direction of the main body so that the flat portion includes a plurality of the joint portions.
The manufacturing method of the aluminum molded article of any one of Claims 1-4. The method for producing an aluminum molded product according to claim 5, wherein, in the projecting step, a shape changing portion extending in the direction perpendicular to the plane is formed at a position continuous with the end portion in the longitudinal direction in the flat portion. 7. The aluminum molded product according to claim 1, wherein in the projecting step, plastic processing is performed on the flange portion so that the flange portion projects in one direction parallel to the plane orthogonal direction. Manufacturing method. In the case where the bending step is a step of bending the aluminum shape by pressing a bending die against the aluminum shape,
The bending die has a concave portion corresponding to the protruding portion in a portion that contacts the flange portion,
In the bending process, the aluminum shaped material is bent in a state where the part having the concave portion in the bending mold is pressed against one surface of the flange part,
In the overhanging step, a pressing die having a convex portion corresponding to the concave portion is pushed against the other surface of the flange portion in a state where the portion having the concave portion in the bending die is pressed against one surface of the flange portion. The manufacturing method of the aluminum molded product of any one of Claims 1-7 which forms the said overhang | projection part by applying. The said aluminum shape material is a manufacturing method of the aluminum molded product of any one of Claims 1-8 currently formed by the extrusion process so that the said main-body part has a closed cross-section structure.

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