JPH10314922A - Composite member and method of manufacturing the same - Google Patents

Abstract

(57) [Abstract] [Problem] To improve accuracy and mechanical strength,
Moreover, the present invention provides a composite member capable of shortening the manufacturing time and improving the production efficiency, and a method for manufacturing the same. A coupling hole (20) formed from an inclined wall (19) is defined in a frame member (12) having a hollow portion (16). The hollow portion 16 is filled with molding sand 40, and a mold 42 is mounted on the frame member 12. At this time, the cavity 44 of the mold 42 communicates with the coupling hole 20. When the molten metal 48 is poured into the cavity 44 and the molten metal 48 is cooled and solidified, a connecting member is integrally formed with the frame member 12.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a composite member composed of a plurality of members, such as a frame member used for an automobile, and a method of manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, as a method of manufacturing a composite member composed of a plurality of members such as a frame member of an automobile, for example, a "structural member and a method of manufacturing the same" disclosed in JP-A-6-71364. (Hereinafter referred to as Conventional Example 1). In this conventional example 1, an engagement groove or a notch for locking is formed in an extruded profile made of a bent aluminum alloy, and another aluminum alloy product is formed in this engagement groove or notch for locking. Are manufactured by combining extruded members or plate members of the above, and joining the joints by welding, bonding or mechanical bonding to produce a structural member.

[0003] Also, Japanese Patent Application Laid-Open No. 55-110678 discloses a "method of manufacturing a frame for a motorcycle made of die-casting"
Conventional example 2) discloses a method in which an end of a frame pipe is crushed and arranged in a mold, and then a molten metal is supplied into the mold to form a joint by die casting.

[0004]

However, in the conventional example 1, when the joints are bonded, the mechanical strength is low, and when the joints are integrated by welding, the structure is heated by the heat at the time of welding. There is a possibility that heat distortion occurs in the extruded shape material forming the member, and the dimensional accuracy may be reduced.
Since a long time is required for welding, there is a problem that the production time becomes long and the production efficiency cannot be improved.

On the other hand, in the conventional example 2, since the end of the frame pipe is crushed, a coating or the like for preventing oxidation is broken to form an oxide film, and the frame pipe on which the oxide film is formed is used. When the joint is formed by die casting, the frame pipe and the joint may be separated from each other by the oxide film, and there is a disadvantage that the mechanical strength is reduced.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and is a composite capable of improving accuracy, mechanical strength, and reducing production time to improve production efficiency. An object is to provide a member and a manufacturing method thereof.

[0007]

According to the present invention, there is provided a composite member comprising a plurality of members, wherein a connection hole formed by an inclined wall is defined. A first member, a second member formed integrally with the first member by mounting a mold on the first member, and forming the coupling hole formed on the second member. And a locking portion that engages with the wall portion.

According to the present invention, the first member is provided with the second member.
The member is integrally formed by casting, and the locking portion is locked to the inclined wall forming the connection hole, so that the second member is prevented from falling out of the connection hole.

In this case, when a low-melting alloy is welded to the surface of the first member, and the first member and the second member are joined by a metal bond via the low-melting alloy, the first member is melted. And the second member are firmly fixed, and a composite member having excellent mechanical strength can be obtained, which is preferable.

Further, the present invention is a method for manufacturing a composite member composed of a plurality of members, wherein a coupling hole formed by an inclined wall is defined in a first member constituting the composite member. Attaching a mold to the first member, and allowing the cavity of the mold to communicate with the coupling hole;
Pouring molten metal into the cavity of the mold and integrally forming a second member with the first member to obtain a composite member.

According to the present invention, the second member is attached to the first member.
The member is integrally formed by casting, and the first member is engaged with the inclined wall forming the connection hole to prevent the second member from falling out of the connection hole.

In this case, after the step of defining the connection hole, a step of removing an oxide film adhered to the surface of the first member, and a step of welding a molten low melting point alloy to the surface of the first member. When the first member and the second member are provided, the first member and the second member are integrally connected by metal bonding via the low melting point alloy, and a composite member having excellent mechanical strength can be obtained, which is preferable. .

[0013]

DESCRIPTION OF THE PREFERRED EMBODIMENTS A composite member according to the present invention will be described.
Preferred embodiments in relation to the manufacturing method will be described below in detail with reference to the accompanying drawings.

In FIG. 1, reference numeral 10 denotes a composite member according to an embodiment of the present invention. This composite member 10
Are, for example, frame members (first
The frame member 12 includes a coupling member (second member) 14 protrudingly formed on an outer wall of the frame member 12 to assemble the frame member 12 with another frame member or the like.

The frame member 12 is formed to be long by extrusion molding, pultrusion molding or the like, and has a hollow portion 16 having a square cross section.
Is defined. The frame member 12 is subjected to a bending process. On the other hand, the coupling member 14 is formed in a substantially U-shape, and has holes 18a, 1
8b is defined. When assembling another frame member or the like to the coupling member 14, a shaft member or the like is inserted into the holes 18a and 18b.

As shown in FIG. 2, a coupling hole 20 is defined in the frame member 12. The wall portion 19 forming the coupling hole 20 is inclined so as to become wider toward the hollow portion 16 of the frame member 12. The coupling hole 2
Reference numeral 0 denotes a locking portion 21 formed below the coupling member 14.
Are engaged, and the wall portion of the locking portion 21 is formed to be inclined corresponding to the wall portion 19. For this reason, the connecting member 14 is prevented from falling out of the connecting hole 20 by the locking portion 21.

The composite member 10 according to the present embodiment is basically configured as described above. Next, a method for manufacturing the composite member 10 will be described.

First, a coupling hole 20 is defined in one wall surface of the frame member 12 which is formed of aluminum or an aluminum alloy and which has been subjected to bending processing in advance (FIG. 3).
reference). In this case, as shown in FIG.
A die 22 is inserted into the second hollow portion 16, while a pad 24 abuts on the outer wall of the frame member 12 corresponding to the die 22, and the die 22 and the pad 24 relatively approach each other. By doing so, the wall of the frame member 12 is sandwiched. Holes 26 and 28 are defined in the die 22 and the pad 24, respectively, and the punch 30 is relatively displaced toward the holes 26 and 28, so that the coupling hole 20 is formed in the frame member 12. Is defined. The hole 26 of the die 22 is
The wall portion forming the frame member 12 is slightly larger than the hole portion 2
The shearing action works toward the edge of No. 6. For this reason, the size of the wall portion 19 forming the coupling hole 20 depends on the size of the frame member 12.
Outside, the outer dimensions of the punch 30 are equal, and inside the frame member 12, the dimensions of the hole 26 of the die 22 are equal. As a result, the wall 19 forming the coupling hole 20 is It is formed to incline so as to become wider toward it.

Next, as shown in FIG.
2 is coated with flux by a nozzle 36 connected to a flux coating device (not shown), and the frame member 12 is heated to approximately 300 ° C. by a heating device (not shown) to remove an oxide film on the surface of the frame member 12. I do.

Next, as shown in FIG. 6, a low melting point alloy 38 (for example, Al-Z
The low melting point alloy 38 is welded to the surface of the frame member 12 by immersing the frame member 12 in n-Si).

Next, as shown in FIG.
The molding sand 40 is filled into the second hollow portion 16 to the inner wall. Next, the mold 42 is mounted on the outer wall of the frame member 12. In this case, the cavity 44 of the mold 42 communicates with the coupling hole 20.

Then, the molten metal 4 of aluminum or aluminum alloy is supplied through a pouring hole 46 communicating with the cavity 44.
8 is poured and casting is performed.

When the molten metal 48 is cooled and solidified, the connecting member 14 is formed integrally with the frame member 12 as shown in FIG. In this case, when the molten metal 48 is poured into the cavity 44 of the mold 42, the coupling member 14 has a size corresponding to the cavity 44 (see a two-dot chain line in FIG. 2), but the molten metal 48 is cooled and solidified. Then, as shown by a solid line in FIG. 2, the size becomes slightly smaller due to thermal contraction.

The connecting member 14 of the composite member 10 thus formed is engaged with the inclined wall 19 of the connecting hole 20 and is prevented from coming off. Also, the frame member 12 is interposed via a low melting point alloy 38 welded to the surface of the frame member 12.
The frame member 12 and the coupling member 14 are coupled with a high mechanical strength because the metal member and the coupling member 14 are coupled to each other.

In the present embodiment, the coupling holes 20 are defined by the punch 30. However, as shown in FIG. 8, the coupling holes 20 may be defined by cutting with an end mill 50. In this case, by cutting the end mill 50 at an angle of approximately 45 °, the wall portion 1 of the coupling hole 20 is cut.
9 can be formed inclined.

In the casting method according to the present embodiment,
Although the case of gravity casting has been described as an example, a squeeze casting method of applying high pressure to the molten metal using a hydraulic press or the like,
Of course, a thixocasting method in which a molten metal in a semi-molten state (semi-molten slurry) is pressed into the cavity by mechanical impact may be used.

[0027]

According to the composite member and the method of manufacturing the same according to the present invention, the following effects and advantages can be obtained.

Since the second member is formed by casting, the manufacturing time is shortened, the production efficiency is improved, and the dimensional accuracy of the composite member is increased, as compared with the case of welding as in the prior art. Further, since the first member and the second member are fixed to each other via the low melting point alloy by metal bonding, a composite member having high mechanical strength can be obtained. Further, since it is not necessary to cast the entire composite member, the size of the mold can be reduced, and the manufacturing cost can be reduced.

Further, by forming the composite member from aluminum or an aluminum alloy, a lightweight composite member having high mechanical strength can be obtained.

When this composite member is used for a frame member of an automobile or the like, there are advantages that the production efficiency of the automobile is improved, the production cost is reduced, and the mechanical strength of the frame member is improved.

[Brief description of the drawings]

FIG. 1 is a schematic perspective view showing a composite member according to an embodiment of the present invention.

FIG. 2 is a partially enlarged longitudinal sectional view showing an engaging member formed on the composite member of FIG.

FIG. 3 is a schematic perspective view of a frame member constituting the composite member of FIG. 1;

FIG. 4 is a schematic partial longitudinal sectional view showing a step of forming a connecting hole by a punch in the frame member of FIG. 3;

FIG. 5 is a schematic perspective view showing a step of applying a flux to the frame member of FIG. 3;

FIG. 6 is a schematic perspective view showing a step of welding a low melting metal to the frame member of FIG. 3;

FIG. 7 is a schematic partial longitudinal sectional view showing a step of casting an engaging member on the frame member of FIG. 3;

8 is a schematic partial longitudinal sectional view showing a step of defining a connection hole in the frame member of FIG. 3 by an end mill.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 ... Composite member 12 ... Frame member 14 ... Coupling member 19 ... Wall part 20 ... Coupling hole 21 ... Locking part 38 ... Low melting point alloy 42 ... Die 48 ... Molten metal

Claims (4)

[Claims] 1. A composite member comprising a plurality of members, wherein a first member having a connection hole formed by an inclined wall is defined, and a mold is mounted on the first member to perform casting. A second member integrally formed with the first member, and a locking portion formed on the second member and engaging with a wall forming the coupling hole. Composite member. 2. The composite member according to claim 1, wherein a low melting point alloy is welded to a surface of said first member, and said first member and said second member are joined by metal bonding via said low melting point alloy. A composite member characterized by being joined. 3. A method for manufacturing a composite member comprising a plurality of members, wherein a step of defining a coupling hole formed by an inclined wall portion in a first member constituting the composite member; Attaching a mold to the first member, communicating the cavity of the mold with the coupling hole, pouring molten metal into the cavity of the mold, and integrally integrating the second member with the first member Forming a composite member to form a composite member. 4. The method of manufacturing a composite member according to claim 3, wherein, after the step of defining the bonding hole, a step of removing an oxide film attached to a surface of the first member; Welding a low-melting alloy melted to the surface, wherein the first member and the second member are integrally joined by a metal bond via the low-melting alloy. Manufacturing method of the member.