JP3333394B2 - Panel manufacturing method and panel - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a novel panel and the panel, and can be used for all structures using panels such as vehicles, automobiles, ships, aviation, elevators, pressure vessels, and the like.

[0002]

2. Description of the Related Art As a method for manufacturing a honeycomb honeycomb panel, Japanese Patent Application Laid-Open Nos . 50-60452 and 58-13 are disclosed.
4736 JP, Sho 58-196165, JP-Sho 62-166073, JP-A No. 1-48697
JP, a manufacturing method according to JP-A 1-280613 Patent brazing method in JP, Sho 63-188036 JP <br/> the electron beam - the manufacturing method according to beam, JP 63-268
583, JP-A No. 1-43349 discloses the Le - Zabi - by beam, by JP-A-1-40180 discloses the resistance welding method, Japanese Unexamined 1-176454, JP-A No. 1
Japanese Patent Application Laid-Open No. Hei .
Japanese Patent Application Laid-Open No. 116133/1986 discloses a fusion welding method.
8-108128, JP JP 62-255132
Publication Sho 63-206545 JP, Hei 1-4
Japanese Patent No. 2297 discloses a manufacturing method using an adhesive. Also, as a structure of a honeycomb panel manufactured by a brazing method, Japanese Patent Application Laid-Open No. 2-109297 is known.

[0003] Furthermore, honeycomb panels manufactured by extrusion and drawing processes are also known.

On the other hand, Japanese Patent Application Laid-Open No.
In JP 05 090, tool consist substantially rigid material than the workpiece - Le inserted into the welding portion of the workpiece, the tool - by moving while rotating the Le, the rotary tool - and Le and the workpiece 2. Description of the Related Art A joining method for joining workpieces by plastic flow due to frictional heat generated during welding is known.

[0005] Conventional friction welding method, the workpiece together rotate with respect to a method for welding by friction heat of the workpieces between said Kohyo 7-505090 discloses a state of fixing the welding member, the It can be joined by moving the tool while rotating it. Therefore, there is an advantage that even a member that is substantially infinitely long in the welding direction can be continuously solid-phase bonded in the longitudinal direction. Furthermore, since solid-state welding is performed using plastic flow of metal due to frictional heat between the rotating tool and the welding member, the joining can be performed without melting the joint. Also,
Since the heating temperature is low, deformation after bonding is small. Since the joint is not melted, there are many advantages, such as fewer defects.

[0006]

The above-described manufacturing method in which a honeycomb material is melted and welded by a heat source such as an arc, a plasma, an electron beam, or a laser beam causes a large deformation after the manufacturing. , Defects are likely to occur in the weld. In the case of an electron beam, there is a problem that the size and shape of the honeycomb panel are limited because welding is performed in a vacuum. Also, the production cost of lasers and electronic beams is high because the equipment is expensive.

[0007] In the case of the brazing method, there is a problem in the reliability of the brazed portion due to the selection of the brazing material, corrosion by flux, and the like. Furthermore, in the case of brazing in a vacuum, there is a problem that the size and shape of the honeycomb panel are limited.

[0008] The manufacturing method using an adhesive has problems in the strength and reliability of the bonded portion.

A honeycomb panel manufactured by extrusion or drawing has a problem in that the thickness and width of the honeycomb material are limited, and as a result, the weight of the honeycomb panel increases. Further, there is a limit to the size of the honeycomb panel that can be manufactured.

[0010] On the other hand, a method of joining by inserting a rotary tool according to the above-mentioned Japanese Patent Publication No. 7-505090 into a workpiece and moving the rotary tool while rotating the tool is disclosed . When applied to panels, there are the following problems.

(1) During welding, the honeycomb panel is deformed by the load of the rotating tool. For this reason, when the face plate and the core material such as the honeycomb panel are thin, it is difficult to join them.

(2) Due to the friction between the rotary tool and the surface of the honeycomb panel, the surface of the joint is dented. For this reason, the thickness of the joint is substantially reduced, so that the strength of the joint is reduced and there is a problem in reliability.

(3) When there is a gap in the joint portion of the joint portion, a defect is easily generated. That is, conventional MIG or T
The allowable range of the gap is narrower than the fusion welding method such as IG.

An object of the present invention is to provide a method of manufacturing a panel which is less likely to be deformed by a load of a rotating tool at the time of joining.

[0015]

The above object is achieved, for example, by the following two steps:
A corrugated core material is arranged between two face plates, and in a method of manufacturing a panel for joining the two, a rotating tool made of a material substantially harder than the material of the panel is rotated while the face plate and the core material are rotated. This can be attained by inserting and moving the face plate and the core material from outside the panel so as to cause plastic flow from the outside of the panel to join the face plate and the core material.

[0016] According to [Operation] In the present invention, since the core material is a rigid corrugated, wave
The core-shaped material supplements the role of the reinforcing material, and a panel with little deformation can be manufactured even in the case of a thin face plate or a face plate made of the core material.

[0017]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiment 1 FIG. 1 is a perspective view showing a method for manufacturing a honeycomb panel according to the present invention. FIG. 2 shows a cross section of FIG. The method for manufacturing a honeycomb panel according to the present invention provides a method for manufacturing a face plate 1 made of an aluminum alloy.
The reinforcing material 3 is disposed between the core material 2 and the core material 2, and these are simultaneously bonded by a solid-phase bonding method. That is, as shown in FIGS. 1 and 2, the rotary tool 4 is inserted into the joint between the face plate 1, the core member 2, and the reinforcing member 3 and moved while rotating the rotary tool. The face plate 1, the core material 2, and the reinforcing material 3 can be simultaneously joined without melting. According to the present invention, the joining portion 5 is formed, and a high quality honeycomb panel can be manufactured at low cost. In other words, the reinforcing member 3 facilitates manufacturing even a honeycomb panel in which the thickness of the face plate 1 or the core member 2 is small and cannot be joined by being deformed by the load of the rotating tool.

The diameter of the tip of the rotary tool 4 used in this embodiment is 6 mm, the length is 4 mm, and the diameter of the brim portion is 20 mm.
mm. The rotation speed of the rotary tool 4 is 1000
rpm, the moving speed is 500 mm / min. In addition,
An ordinary M screw is formed at the tip of the rotary tool.

Embodiment 2 FIG. 3 shows a cross section of a honeycomb panel having the same shape as the honeycomb panel of FIG. In the present embodiment, a method for manufacturing a honeycomb panel which is simultaneously bonded from both front and back surfaces of the honeycomb panel will be described. That is, the rotating tool 4 is disposed on the front and back of the honeycomb panel, and the face plate 1, the core material 2, and the reinforcing material 3 are joined from both sides by moving the tool 4 while rotating. Thus, a highly accurate honeycomb panel structure can be efficiently manufactured at low cost. The bonding conditions in this case are the same as in the first embodiment.

Embodiment 3 FIG. 4 shows that a reinforcing material 3 is provided at a part of a panel end portion made of an aluminum alloy.
2 shows the structure of a panel provided with. That is, since the core material 2 is corrugated and strong, it supplements the role of the reinforcing material. For this reason, even if the face plate 1 is thin, it can be joined without deformation due to the load of the rotary tool 4. Accordingly, a sound joining portion 5 is formed between the face plate 1 and the core material 2, and a structure made of a honeycomb panel having a lightweight structure can be manufactured.

Embodiment 4 FIG. 5 shows a manufacturing method in which a rotary tool is inserted into two joints between a face plate 1 made of an aluminum alloy and a core material 2 and the two joints are joined at the same time. In the present invention, the core
Material 2 supplements the role of reinforcement. That is, core material 2
Is sufficiently strong to withstand the load of the rotary tool 4, so that even if the face plate 1 is thin, the face plate 1 and the core 1 are not deformed.
The material 2 can be joined. Thus, a highly accurate honeycomb panel structure can be manufactured. The joining conditions are the same as in the first embodiment.

Embodiment 5 FIG. 6 shows a honeycomb panel composed of a face plate 1, a core material 2 and an edge material 6 manufactured by extrusion, and a rotary tool 4 inserted into the edge material 6. The joining portion 5 is formed to manufacture a large honeycomb panel structure. In other words, when the face plate 1, the core material 2, and the edge material 6 are integrally formed by the extrusion method, the edge material 6 at the end of the honeycomb becomes the reinforcing material of the present invention, and the face plate 1 and the core material 2 are thin. But
The joining can be performed without being deformed by the load of the rotary tool 4. Therefore, a lightweight, high-precision, large-sized honeycomb panel structure can be efficiently and inexpensively manufactured. A high-speed vehicle was manufactured using this honeycomb panel as a railway vehicle body.

Embodiment 6 FIG. 7 shows a honeycomb panel composed of a face plate 1, a core material 2, and an edge material 6 manufactured by extrusion, and a rotary tool 4 is inserted into the edge material portion and joined. Thus, a large honeycomb structure is manufactured by combining a plurality of honeycomb panels. In the present embodiment, the thickness of the joint portion where the rotary tool 4 contacts is increased by 0.8 mm. As a result, the strength is not substantially reduced even when the joint is depressed by the rotary tool 4. Furthermore, even if the gap at the joint is large, joining can be performed without defects. For this reason, the structure consisting of highly reliable honeycomb panels is efficiently used.
And it can be manufactured at low cost. A high-speed vehicle was manufactured using this honeycomb panel as a railway vehicle body.

Embodiment 7 FIG. 8 shows a state in which a honeycomb panel composed of a face plate 1 and a core member 2 manufactured by extrusion processing is joined to each other, and a reinforcing member 3 is disposed between the honeycomb panels and a rotary tool is attached to the reinforcing member. 4
Insert and join. Thus, a large honeycomb structure is manufactured by combining a plurality of honeycomb panels. In the present embodiment, the thickness of the reinforcing material at the joint where the rotary tool 4 contacts is increased by 1 mm. As a result, the strength does not substantially decrease even when the joint is depressed by the rotary tool 4. Furthermore, even if the gap at the joint is large, joining can be performed without defects. For this reason, a structure made of a highly reliable honeycomb panel can be manufactured efficiently and at low cost. A high-speed vehicle was manufactured using this honeycomb panel as a railway vehicle body.

Embodiment 8 FIG. 9 is a perspective view of a honeycomb panel manufactured by the brazing method using plastic flow caused by frictional heat between the rotary tool 4 and the honeycomb material.

FIG. 10 shows a sectional structure of FIG. FIG.
As shown in FIG. 10, the face plate 1, the core material 2, and the edge material 6
They are joined by a brazing layer. The joining of the honeycomb panels according to the present invention is performed at the edge member 6. In other words, the edge
The material 6 supplements the role of the reinforcing material against the load of the rotating tool,
Even when the face plate 1 and the core material 2 are thin, they can be joined without deformation. According to the above-described method, a large-sized honeycomb panel structure can be manufactured by a solid-phase joining method between honeycomb panels joined by a brazing method.

Using this honeycomb panel as a railway vehicle body, a high-speed vehicle was manufactured.

Embodiment 9 FIG. 11 shows a perspective view of a method for manufacturing a railway vehicle according to the present invention. First, the rotary tool 4 is inserted into the edge material 6 of a honeycomb panel having a length of 25 m and a width of 0.4 m manufactured by an extrusion method, and the honeycomb panels are solid-phase bonded from both sides.

FIG. 12 shows a detailed sectional structure of the manufacturing method of FIG. A honeycomb panel including a face plate 1, a core material 2, and a rim material 6 manufactured by an extrusion method is disposed on a fixed base, and is fixed by a fixing jig 7 from right and left and up and down directions. In this embodiment, the height of the face plate at the joint is about 0.6 mm higher than other portions. Joining rotation tool in the vertical direction in the portion of the strip 6 of the honeycomb Pas <br/> panel - inserting Le 4. The rotary tool is attached to the robot 8 and
It moves in the direction of the welding line while rotating by the driving force of the tab 9. By the above method, the honeycomb panels are solid-phase bonded to each other. The rotary tool can be automatically moved up and down according to the deformation of the honeycomb panel surface. further,
該回 Utatetsu - le 4 can automatically move the control in the lateral direction along the weld line.

FIG. 13 is a perspective view of a railway vehicle manufactured by the above method. Part of the length of the joint 5 is 12.5 m
However, a maximum length of 25 m is formed from the front and back use surfaces, and a railway vehicle is manufactured.

Embodiment 10 FIG. 14 shows a joint structure of a joint according to the present invention. Figure 1
4 (a) to 4 (e) show examples in which a reinforcing material 3 is provided in joining the face plates 1 of the honeycomb panel. That is,
At the lower part of the left and right face plates 1 to be joined, a reinforcing material 3 not deformed by the load of the rotating tool 4 is arranged.
Also joined at the same time. As a result, the face plate 1 of the joining member can be solid-phase joined even with a substantially infinite honeycomb without being deformed by the load of the rotating tool. FIGS. 15A and 15B show an example in which one of the face plates 1 is manufactured integrally with the reinforcing member 3. That is, the load of the rotating tool is supported by the reinforcing member 3 integrated with the face plate 1.

FIGS. 16A to 16D show a joint structure in which both the face plate 1 and the reinforcing member 3 are manufactured integrally. In this case, the load of the rotating tool is supported by both reinforcing members 3.

FIGS. 17A to 17E show a joint structure in which the thickness of the joint is thicker than the other parts. (A)
(B) shows an I-shaped joint structure, (c) and (d) show a V-shaped joint structure, and (e) and (f) show a V-shaped joint structure. In other words, by increasing the thickness of the joint by 0.3 mm or more from the other portions, the space in the gap of each joint structure is replenished with the increased thickness of the joint. The range can be increased. In addition, since the space can be replenished even in the case of the re-type and the V-type, bonding can be performed without defects.

[Structure of the Present Invention] The structure of the present invention is achieved by one or more of the following. (1) A reinforcing material is provided at a joint or a reinforcing structure is provided.

(2) The thickness of the joining portion is made thicker than other portions.

(3) Joining from both front and back surfaces of the honeycomb panel.

[0037]

According to the present invention, since the corrugated core material is used, even when the face plate and the core material are thin, the core material can be used.
Since the material is corrugated and strong, the core material supplements the role of the reinforcing material, and a panel with little deformation can be manufactured even in the case of a thin face plate or a face plate made of the core material.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a method for manufacturing a honeycomb panel of the present invention.

FIG. 2 is a longitudinal sectional view of FIG.

FIG. 3 is a cross-sectional view illustrating a manufacturing method according to another embodiment.

FIG. 4 is a longitudinal sectional view showing a manufacturing method of another embodiment.

FIG. 5 is a cross-sectional view illustrating a manufacturing method according to another embodiment.

FIG. 6 is a cross-sectional view illustrating a manufacturing method according to another embodiment.

FIG. 7 is a cross-sectional view illustrating a manufacturing method according to another embodiment.

FIG. 8 is a cross-sectional view illustrating a manufacturing method according to another embodiment.

FIG. 9 is a perspective view of solid-state joining of honeycomb panels manufactured by a brazing method.

FIG. 10 is a longitudinal sectional view of a main part of FIG. 9;

FIG. 11 is a perspective view showing an embodiment for manufacturing a panel of a railway vehicle.

FIG. 12 is a longitudinal sectional view of a main part of FIG. 11;

FIG. 13 is a perspective view of a vehicle body of a railway vehicle.

FIG. 14 is a longitudinal sectional view showing various joint structures of the present invention.

FIG. 15 is a longitudinal sectional view showing various joint structures of the present invention.

FIG. 16 is a longitudinal sectional view showing various joint structures of the present invention.

FIG. 17 is a longitudinal sectional view showing various joint structures of the present invention.

[Explanation of symbols]

 1: face plate, 2: core material, 3: reinforcing material, 5: joint.

──────────────────────────────────────────────────続 き Continuing on the front page (51) Int.Cl. ⁷ Identification code FI B23K 101: 02 B23K 101: 02 (72) Inventor Kinya Aoya 794, Higashitoyoi, Kudamatsu-shi, Yamaguchi Prefecture Hitachi, Ltd. Kasado Plant (72) Inventor Masakuni Esumi 794, Higashi-Toyoi, Kazamatsu, Kamamatsu-shi, Yamaguchi Prefecture Inside the Kasado Plant, Hitachi, Ltd. Masato Kato (58) Field surveyed (Int. Cl. ⁷ , DB name) B23K 20/12

Claims (7)

(57) [Claims] 1. A method of manufacturing a panel in which a corrugated core material is arranged between two face plates and the two face plates are joined, wherein the face plate is rotated while rotating a rotary tool made of a material substantially harder than the material of the panel. And by inserting and moving the joint between the core plate and the core material to cause the face plate and the core material to flow plastically from outside the panel, thereby joining the face plate and the core material. How to make panels. 2. The method according to claim 1, wherein a portion of one of the face plates which is joined to the core material is closer to the other face plate,
A reinforcing material is arranged between the other face plate and the core material of the joint portion, and when the joint portion between the one face plate and the core material is joined by the rotating tool, Joining one end of the reinforcing plate. 3. The method according to claim 2, wherein the one face plate, the core material, and one end of the reinforcing plate are joined by the rotary tool when the other face plate and the other end of the reinforcing plate are connected to each other. And joining with another rotating tool. 4. A method of manufacturing a panel for joining the face plate and the corrugated core material, the joint between the core material and the surface plate while rotating the rotating tool comprising a substantially rigid material than the material of the panel inserting, by moving, method of manufacturing the panel, characterized in that, for bonding the surface plate and the core material to said as to cause plastic flow the faceplate core material from the core material is not surface side. 5. A panel having a corrugated core material disposed between two face plates, wherein the face plate and the core material are joined from outside the panel by plastic flow of the metal of the face plate and the core material. A panel characterized by the above. 6. The method according to claim 5, wherein a portion of one of the face plates which is joined to the core material is on the other face plate side,
A reinforcing material is arranged between the other face plate and the core material of the joint, and the one face plate, the core material, and the reinforcing plate are joined by plastic flow of metal, A panel characterized by: 7. A panel in which a wavy core material is joined to a face plate, wherein the face plate and the core material are formed by plastic flow of the metal of the face plate and the wavy core material from the side having no wavy core material. A panel that is joined by: