JP2017192964A - Cast-in member and method for manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an insert member in which a core inserted when casting a cast part can be easily pulled out, and a method for manufacturing the insert member.SOLUTION: One end side of a cylindrical pipe part 25 is inserted thereby forming a cast part 26. On one end side of the pipe part 25 which is inserted by the cast part 26, a taper part 32, which is gradually reduced toward a tip side, is formed. When casting the cast part 26, it can be suppressed that the pipe part 25 bites to a core, which is inserted in the pipe part, by reduction of the pipe part 25 due to mold shrinkage of the cast part 26. After molding the cast part 26, the core can be easily pulled out.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a cast-in member in which one end side of an insert member is cast by a cast part, and a method for manufacturing the same.

  2. Description of the Related Art Conventionally, an instrument panel portion is provided in a front part of a passenger compartment of an automobile, and a long steering hanger beam is attached to the instrument panel portion in the vehicle width direction. This steering hanger beam attaches a steering shaft, which is a steering device connected to the steering wheel of the driver's seat, and an airbag device provided in the instrument panel to the vehicle body side, and spans between the left and right front pillars. Are arranged.

  As such a steering hanger beam, for the purpose of weight reduction, there is one in which only a part is made of steel and the other part is made of a light metal material such as aluminum or magnesium. In this case, when the steel portion and the light metal portion are welded, it takes time and cannot be manufactured at low cost, so that the steel portion is used as an insert member, and one end of the insert member is cast with a light metal (for example, a patent) Reference 1).

JP 2012-101266 A (Page 5, Fig. 3-4)

  When manufacturing as described above, it is necessary to set a core to be inserted into the insert member from the other end of the insert member so that molten metal does not enter the insert member. In this case, since the inner surface of the insert member and the core are in direct contact with each other, there is a possibility that the core and the insert member may bite and the core cannot be removed due to the shrinkage of the insert member accompanying the solidification shrinkage of the casting portion. .

  This invention is made | formed in view of such a point, and it aims at providing the cast-in member which can draw out the core inserted when casting a casting part easily, and its manufacturing method.

  The cast-in member according to claim 1 includes a metal insert member formed in a cylindrical shape, and a metal cast part that casts one end side of the insert member, and the insert member includes the cast product. The taper part which gradually reduces toward the front end side is provided in the one end side cast by the part.

  The cast-in member according to claim 2 is the cast-in member according to claim 1, wherein the tip of the tapered portion is an anchor portion embedded in the cast portion.

  The cast-in member according to claim 3 is the cast-in member according to claim 1 or 2, wherein the insert member includes an inner lid portion that closes the inside of the tapered portion.

  According to a fourth aspect of the present invention, there is provided a method for producing the cast-in member, wherein one end side of the cylindrical metal insert member is formed as a taper portion that gradually decreases toward the tip end side, and the insert member is inserted from the other end portion into the middle. In this state, the taper portion of the insert member is inserted into the cavity of the mold, and a casting portion is formed by filling the cavity with a metal material and casting the taper portion.

  The method for producing a cast-in member according to claim 5 is the method for producing a cast-in member according to claim 4, wherein when the cast part is formed, the tip end of the core is connected to the other end of the insert member. By being inserted so as to be positioned on the side, a metal material is poured into the tip portion of the taper portion, and the anchor portion is embedded in the casting portion.

  According to a sixth aspect of the present invention, there is provided a method for producing a cast-in member, wherein the insert member is formed with an inner lid portion for closing the inside of the tapered portion.

  According to the cast-in member according to claim 1, when the cast part is cast by forming the tapered part gradually decreasing toward the tip side on the one end side cast by the cast part of the insert member. Biting due to shrinkage of the insert member due to molding shrinkage of the cast part with respect to the core inserted into the insert member can be suppressed, and the core can be easily pulled out after molding of the cast part.

  According to the cast-in member according to claim 2, in addition to the effect of the cast-in member according to claim 1, the tip portion of the tapered portion is an anchor portion embedded in the cast portion, whereby the insert member with respect to the cast portion is The pull-out strength can be improved.

  According to the cast-in member according to claim 3, in addition to the effect of the cast-in member according to claim 1 or 2, the insert member is provided with the inner lid portion that closes the inside of the taper portion, whereby the taper of the insert member is provided. Since the rigidity with respect to the reduction at the portion can be improved, the biting against the core due to the reduction of the insert member due to the molding shrinkage of the cast portion can be more reliably suppressed.

  According to the method for manufacturing a cast-in member according to claim 4, the one end side of the cylindrical metal insert member is formed as a tapered portion that gradually decreases toward the tip end side. By forming a casting part that fills the taper part by filling the mold cavity into which the taper part of the insert member is inserted with the core inserted from the end part, the taper part is cast. Biting of the core due to the reduction of the resulting insert member can be suppressed, and the core can be easily pulled out after molding of the cast part.

  According to the method for manufacturing a cast-in member according to claim 5, in addition to the effect of the method for manufacturing a cast-in member according to claim 4, when forming the cast part, the tip of the core is connected to one end of the insert member. By inserting the metal material into the tip portion of the taper portion and setting the tip portion of the taper portion to be an anchor portion embedded in the casting portion, by being inserted so as to be located on the other end side with respect to the portion, The pull-out strength of the insert member with respect to the cast part can be improved.

  According to the method for producing a cast-in member according to claim 6, in addition to the effect of the method for producing a cast-in member according to claim 4 or 5, the insert member is provided with an inner lid portion that closes the inside of the tapered portion. Thereby, since the rigidity with respect to the reduction | decrease in the taper part of an insert member can be improved, the biting with respect to the core by the reduction | decrease of the insert member resulting from the shaping | molding shrinkage | contraction of a casting part can be suppressed more reliably.

(A) is a cross-sectional top view which shows the cast-in member of the 1st Embodiment of this invention, (b) is a front view which shows a cast-in member same as the above. It is a perspective view which shows a vehicle body structural component provided with a cast-in member same as the above. It is a cross-sectional top view shown in order of the manufacturing method (a) thru | or (d) of a cast-in-place member same as the above. It is a cross-sectional top view which shows the cast-in member of the 2nd Embodiment of this invention. It is a cross-sectional top view shown in order of the manufacturing method (a) thru | or (d) of a cast-in-place member same as the above. It is a front view which shows the cast-in member of the 3rd Embodiment of this invention. It is a front view which shows the cast-in member of the 4th Embodiment of this invention.

  The configuration of the first embodiment of the present invention will be described below with reference to the drawings.

  In FIG. 2, reference numeral 11 denotes a steering hanger beam which is a vehicle body structural part. This steering hanger beam 11 is also called a steering member or the like, and is arranged along the vehicle width direction inside an instrument panel (not shown) of the vehicle body. Has been placed.

  The steering hanger beam 11 includes a long beam main body 15, side brackets 16 and 16 provided at both ends of the beam main body 15, and a support bracket 17 protruding downward from the beam main body 15. 17 and steering support portions 18 and 18 projecting rearward from the beam main body 15 are provided. As the steering hanger beam 11 of the present embodiment, a so-called left steering wheel is shown in which the driver's seat is located on the left side of the vehicle body. Yes. Further, hereinafter, the vertical direction and the left-right direction are based on the straight traveling state of the vehicle.

  The beam body 15 is also called a main pipe or the like, and is formed in a substantially cylindrical shape. This beam main body 15 includes a first main body portion (one end side main body portion) 21 as a cast-in member positioned on one end side in the longitudinal direction (axial direction) and a cover positioned on the other end side in the longitudinal direction (axial direction). A second main body portion (the other end side main body portion) 22 as a connecting portion is configured to be coaxially connected by welding, for example.

  The first body portion 21 is provided in a substantially cylindrical shape by integrally forming a pipe portion (cylindrical body) 25 as an insert member and a casting portion (bracket member) 26.

  The pipe portion 25 is formed into a cylindrical shape (FIG. 1B) from a metal material, in this embodiment, steel. As shown in FIG. 1A, the pipe portion 25 is integrally provided with a pipe portion main body 31 as a cylindrical insert member main body and a tapered portion 32 continuous with the pipe portion main body 31.

  The pipe part body 31 constitutes the other end side of the pipe part 25, is formed in a straight tube shape, and penetrates between both end parts. That is, the pipe portion main body 31 is set to have a substantially constant diameter. The pipe body 31 is a connecting portion that connects the first body 21 and the second body 22. Further, the pipe part main body 31 is not covered with the casting part 26 and is exposed. Further, a tapered portion 32 is continuous with one end side of the pipe portion main body 31. The other end side of the pipe body 31 is connected to one end of the second body 22 by, for example, welding.

  The taper portion 32 constitutes one end side of the pipe portion 25, and is gradually reduced from the base end side which is the pipe portion main body 31 side toward the distal end side (casting portion 26 side) which is the opposite side. In this form, it is formed so as to be reduced in diameter (reduced). In the present embodiment, the tapered portion 32 is formed to have a substantially constant inclination from the base end portion to the tip end portion. That is, the tapered portion 32 has a truncated conical cylinder shape. The tapered portion 32 is an insert portion inserted into the casting portion 26, and at least the outer side is covered with the casting portion 26 and is not exposed to the outside.

  On the other hand, the cast part 26 is formed in a cylindrical shape from a metal material different from the metal material constituting the pipe part 25, in this embodiment, magnesium which is a light metal material. The cast part 26 is formed in a cylindrical shape having a larger outer diameter than the pipe part 25 (pipe part body 31). Further, the cast part 26 is formed such that a part thereof is inserted into one end part of the pipe part 25. In other words, the casting part 26 includes a protruding part 26 a located inside the pipe part 25. Therefore, the projecting portion 26a is formed so as to gradually expand (expand the diameter) toward the inside of the pipe portion 25 (taper portion 32), that is, the other end side, along the inner surface of the taper portion 32 of the pipe portion 25. Has been. For this reason, the tip end portion of the taper portion 32 of the pipe portion 25 is an anchor portion 32a that is embedded in the casting portion 26 and whose inner surface and outer surface are covered with the casting portion 26, respectively.

  Returning to FIG. 2, the second main body portion 22 is casted of, for example, steel, that is, the same metal material as the pipe portion 25, and is provided in a substantially cylindrical shape.

  The side brackets 16 and 16 are for fixing the steering hanger beam 11 between front pillars (not shown) of the vehicle body. In the present embodiment, for example, one of these side brackets 16 and 16 is formed integrally with the first main body portion 21 (casting portion 26), and the other is formed integrally with the second main body portion 22. Note that. These side brackets 16 and 16 may be formed separately from the beam body 15 and integrated by welding or the like.

  Each support bracket 17 fixes the steering hanger beam 11 to a vehicle body floor or the like. For example, in the present embodiment, one support bracket 17 projects from the second body 22 at the longitudinal center of the beam body 15, and the other support bracket 17 is located near the side bracket 16 in the second body. Projected to the portion 22. Accordingly, each support bracket 17 is formed of the same metal material as that of the second main body portion 22. The support brackets 17 may be formed integrally with the beam main body 15 (second main body portion 22) in advance, or formed separately from the same or different metal material as the beam main body 15 (second main body portion 22). And may be integrated by welding or the like.

  The steering supports 18, 18 are a steering device including a steering wheel as a steering wheel disposed in the driver's seat, a steering shaft (steering column shaft) as a steering device connected to the steering wheel, and a vehicle body side member (not shown). Is located between the two and supports the steering device and is fixed to the vehicle body side member. The steering support portions 18 and 18 are provided so as to protrude from the first main body portion 21 (casting portion 26) of the beam main body 15, for example. Therefore, these steering support portions 18 and 18 are formed of the same metal material as the casting portion 26. The steering support portions 18 and 18 may be integrally formed with the beam main body 15 (first main body portion 21 (casting portion 26)) in advance, or the beam main body 15 (first main body portion 21 (casting portion 26). )) May be formed separately from the same or different metal material and integrated by welding or the like.

  Next, the manufacturing method of said 1st Embodiment is demonstrated.

  In general, the steering hanger beam 11 is formed by separately forming the first main body portion 21 and the second main body portion 22, and welding the end portion of the pipe portion 25 of the first main body portion 21 to the end portion of the second main body portion 22. It is manufactured by concatenating.

  When the first main body portion 21 is formed, first, one end side of the cylindrical pipe portion 25 is formed in advance as a tapered portion 32 that decreases toward the distal end side (forming step).

  Next, using the core 35 shown in FIG. 3A, the core 35 is inserted from the other end of the pipe portion 25, that is, from the pipe portion main body 31 side (insertion step). The core 35 prevents the molten metal material 36 (FIG. 3 (b)) from entering the pipe portion 25 more than a predetermined amount, in other words, the pipe portion of the casting portion 26 (FIG. 1 (a)). The shape inside 25 is set. The core 35 is shaped to be fitted to the inner surface of the pipe portion 25 by a material such as a metal having heat resistance, that is, the distal end portion 35a gradually moves from the proximal end side to the distal end side along the inner surface of the tapered portion 32. It is formed in a columnar shape (columnar shape) that is reduced (reduced diameter). The core 35 is in a state where the distal end portion 35a is spaced from the distal end portion of the pipe portion 25 (tapered portion 32) toward the proximal end side in a state where the core 35 is inserted into the pipe portion 25.

  Further, only the taper portion 32 of the pipe portion 25 into which the core 35 is inserted is inserted into the cavity 38 between the molding dies 37 and 37 using the molding dies 37 and 37 (insert step).

  In this state, as shown in FIG. 3 (b), the molten metal material (magnesium) for forming the casting portion 26 (FIG. 1 (a)) is formed in the cavity 38, unlike the metal material forming the pipe portion 25. 36 is filled (filling step). At this time, the metal material 36 flows between the outer surface of the pipe portion 25 and the cavity 38, and the tip portion 35a of the core 35 is positioned so as to be separated from the tip portion of the pipe portion 25 to the other end side. As a result, part of the pipe portion 25 flows into the tapered portion 32 from the tip portion of the pipe portion 25 and comes into contact with the tip portion 35a of the core 35.

  Then, the metal material 36 is cooled to be solidified, and the cast portion 26 is formed by casting the taper portion 32 of the pipe portion 25 as shown in FIG. 3C (solidification step). At this time, the metal material 36 (FIG. 3B) that has entered the distal end side of the tapered portion 32 of the pipe portion 25 is cooled, so that a part of the casting portion 26 covers the inner surface of the tapered portion 32. 26a, and the tip end portion of the taper portion 32 is formed as an anchor portion 32a embedded in the casting portion. Further, the taper portion 32 of the pipe portion 25 is slightly reduced (contracted) in the radial direction (direction toward the central axis) as the metal material 36 (FIG. 3B) is solidified and contracted.

  Thereafter, the molds 37 and 37 are opened, and the core 35 is pulled out from the other end portion (pipe portion body 31) of the pipe portion 25 as shown in FIG. At this time, according to the present embodiment, the taper portion 32 that gradually decreases toward the tip end side is formed on one end side of the pipe portion 25, so that the core portion extends from the other end portion of the pipe portion 25. A casting part 26 in which a metal material 36 (FIG. 3B) is filled in a cavity 38 of a mold 37, 37 into which a taper part 32 of the pipe part 25 is inserted in a state where 35 is inserted, and the taper part 32 is cast. With the tapered portion 32 that gradually expands in the opposite direction to the insertion direction of the core 35, the cast portion 26 with respect to the core 35 inserted into the pipe portion 25 when casting the cast portion 26 is formed. Biting on the core 35 due to shrinkage of the pipe portion 25 due to molding shrinkage of the core portion can be suppressed, and the core 35 can be easily pulled out from the pipe portion 25 after the casting portion 26 is molded. Therefore, the first main body 21 can be easily detached from the molds 37, 37.

  Further, when forming the casting portion 26, the tip portion 35a of the core portion 35 is inserted so that the tip portion 35a of the core 35 is positioned on the other end side with respect to one end portion of the pipe portion 25. A metal material 36 (FIG. 3B) can be poured into the tip portion of the taper portion 32 to form an anchor portion 32a embedded in the cast portion 26, and the protrusion that has entered the taper portion 32 of the cast portion 26. The portion 26a is positioned so as to be caught on the tip end side of the tapered portion 32 with respect to the removal direction, and the removal strength of the pipe portion 25 with respect to the casting portion 26 can be improved.

  The molds 37 and 37 and the core 35 can have a simple structure, and easy insert casting is possible.

  Next, a second embodiment will be described with reference to FIGS. In addition, about the structure and effect | action similar to said 1st Embodiment, the same code | symbol is attached | subjected and the description is abbreviate | omitted.

  In the present embodiment, the pipe portion 25 of the first main body portion 21 of the first embodiment includes an inner lid portion 41 as shown in FIG.

  The inner lid portion 41 is disposed inside the tapered portion 32 and closes the tapered portion 32, that is, in a direction intersecting (orthogonal) with respect to the axial direction of the tapered portion 32 (pipe portion 25). Are formed along. Accordingly, the inner lid portion 41 is formed across the tapered portion 32 (pipe portion 25). For this reason, the pipe portion 25 is formed so as not to penetrate between both end portions. In the present embodiment, the inner lid portion 41 is located closer to the distal end side of the tapered portion 32 between both ends in the longitudinal direction (axial direction) of the tapered portion 32. That is, the inner lid portion 41 is disposed at a position spaced apart from the proximal end portion and the distal end portion of the tapered portion 32. The inner lid portion 41 may be formed integrally with the pipe portion 25, or may be formed separately from the pipe portion 25 and integrated by welding or the like.

  When the first main body 21 is manufactured, as in the first embodiment, first, a tapered portion that first shrinks one end side of the tubular pipe portion 25 toward the front end side. 5 and an inner lid portion 41 is formed inside the tapered portion 32 (forming step). From the other end of the pipe portion 25, that is, from the pipe portion main body 31 side, the core shown in FIG. 35 is inserted (insertion step). The core 35 is at a position where the tip 35a is in contact with the inner lid 41.

  Next, only the taper portion 32 of the pipe portion 25 into which the core 35 is inserted is inserted into the cavity 38 between the molding dies 37 and 37 using the molding dies 37 and 37 (insert step).

  In this state, as shown in FIG. 5 (b), the cavity 38 is filled with a molten metal material (magnesium) 36 for forming the cast portion 26 (FIG. 4) unlike the metal material constituting the pipe portion 25. (Filling step). At this time, a part of the metal material 36 flows into the tapered portion 32 from the tip portion of the pipe portion 25 and comes into contact with the inner lid portion 41.

  Then, the metal material 36 is cooled to be solidified, and as shown in FIG. 5C, the cast portion 26 is formed by casting the taper portion 32 of the pipe portion 25 (solidification step). At this time, the metal material 36 (FIG. 5B) that has entered the tip side of the taper portion 32 of the pipe portion 25 is cooled, so that a part of the casting portion 26 covers the inner surface of the taper portion 32 and covers the inner lid. The protrusion portion 26 a comes into contact with the portion 41, and the tip portion of the tapered portion 32 is formed as an anchor portion 32 a embedded in the casting portion 26.

  Thereafter, the molds 37 and 37 are opened, and the core 35 is pulled out from the other end portion (pipe portion main body 31) of the pipe portion 25 as shown in FIG.

  At this time, a tapered portion 32 that gradually decreases toward the distal end side is formed on one end side of the pipe portion 25 that is cast by the cast portion 26, and the distal end portion of the tapered portion 32 is embedded in the cast portion 26. By having the same configuration as that of the first embodiment, such as the anchor portion 32a, the same operational effects as those of the first embodiment can be obtained.

  In addition, by providing the pipe portion 25 with the inner lid portion 41 that closes the inside of the taper portion 32, the rigidity of the pipe portion 25 against shrinkage (constriction) at the taper portion 32 can be improved. It is possible to more reliably suppress the biting of the core 35 due to the reduction of the pipe portion 25 caused by the above.

  In each of the above embodiments, for example, as in the third embodiment shown in FIG. 6, the pipe portion 25 may have a hexagonal cylindrical shape, or as in the fourth embodiment shown in FIG. Furthermore, it is good also as a square cylinder shape. That is, the cross-sectional shape of the pipe part 25 can be an arbitrary polygonal shape.

  Further, the core 35 can be formed integrally with the mold 37.

  Furthermore, the configuration of each of the above embodiments can be applied not only to the vehicle body structural component (the steering hanger beam 11) but also to any other cast-in member.

  The present invention can be suitably used for at least a part of a steering hanger beam, for example.

21 1st body part as cast-in member
25 Pipe section as insert member
26 Casting part
32 Taper
32a Anchor part
35 core
35a Tip
36 Metal materials
37 Mold
38 cavity
41 Inner lid

Claims (6)

A metal insert member formed in a cylindrical shape;
A metal casting part for casting one end of the insert member;
The insert member is provided with a tapered portion that gradually decreases toward the tip end side at one end side that is cast around by the casting portion. The cast-in member according to claim 1, wherein the tip of the tapered portion is an anchor portion embedded in the casting portion. The insert member is provided with an inner lid portion that closes the inside of the tapered portion. One end side of the cylindrical metal insert member is formed as a tapered portion that gradually decreases toward the tip side,
With the core inserted from the other end of the insert member, the taper portion of the insert member is inserted into the cavity of the mold, and the casting portion is formed by filling the cavity with a metal material and casting the taper portion. A method for producing a cast-in member, characterized by: When forming the cast part, the metal material is poured into the tip part of the taper part by inserting the tip part of the core so as to be positioned on the other end side with respect to one end part of the insert member. The method of manufacturing a cast-in member according to claim 4, wherein the tip of the tapered portion is an anchor portion embedded in the cast portion. The method for manufacturing a cast-in member according to claim 4 or 5, wherein an inner lid portion for closing the inside of the tapered portion is formed on the insert member.

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