Metallic member bonding device for pressing rod-shaped or cylindrical first metallic member into hole portion of annular second metallic member to bond the same and bonding method therefor

A metallic member bonding device includes a pressurizing unit, a current supply unit, and a deformation suppressing unit. The pressurizing unit pressurizes a first metallic member toward a hole portion of a second metallic member to press the first metallic member therein. The current supply unit supplies a welding current between the first metallic member and the second metallic member. The deformation suppressing unit suppresses deformation of one of the first metallic member and the second metallic member, the one member having a constituent metallic material with at least one of a proof stress and a melting temperature lower than that of the other member, the deformation being in a direction of a cross section crossing a direction of the press-in. Then, the deformation suppressing unit is provided in a region covering at least a plastic flow range in the press-in direction.

TECHNICAL FIELD

The present invention relates to a metallic member bonding device and a bonding method therefor.

BACKGROUND ART

As a method of bonding a first metallic member having a rod shape or a cylindrical shape and a second metallic member having an annular shape, a bonding method is employed in which while pressing one of the members into a hole portion of the other member, a large current is passed through the members in a short period of time. Specifically, first, a cross section of the first metallic member is set to be larger in size than a cross section of the hole portion of the second metallic member. Additionally, a front end portion of the first metallic member is tapered and an opening edge of the hole portion of the second metallic member is also tapered.

Next, with the first metallic member fitted to the hole portion of second metallic member, a large current is passed in a short period of time while pressurizing. As a result, an outer circumferential surface of the first metallic member and one side interface portion of the second metallic member are softened and plastically fluidized so as to cause solid-phase bonding at the interface portion.

In the above bonding method, since a large current is applied in a short period of time, a bonding portion and a periphery thereof are unlikely to have a burn or a strain to therefore enable highly precise bonding. Additionally, as compared with bonding using arc welding or brazing, further cost-down can be realized.

JP 2006-181627 A discloses a technique for bonding different kinds of metals having physical properties (melting temperature, proof stress, and the like) different from each other in order to realize weight reduction and cost-down.

However, when adopting such a bonding method as described above according to the conventional art for bonding different kinds of metals having physical properties different from each other, it is necessary to have a large amount of upset in order to ensure a bonding strength, which leads to an increase in scale and weight of a bonding part.

Description will be made of matters considered for the above problem by the inventors of the present invention with reference toFIG. 10.FIG. 10shows a state where a first metallic member900made of carbon steel and a second metallic member901made of an aluminum alloy (Al alloy) are bonded using the bonding method as described above. As shown inFIG. 10, in the bonding method, a tapered surface900aof the first metallic member900is pressed (arrow A90) against a tapered surface901bof the second metallic member901and plastically fluidized, resulting in solid-phase bonding due to formation of a diffusion layer902.

However, because a melting temperature of the second metallic member901made of an Al alloy is lower than that of carbon steel, the Al alloy at an initial stage of bonding melts to become a burr903to be outwardly discharged. This generates an unbonded portion Ar0. Additionally, because of a difference in proof stress between an Al alloy and carbon steel, the second metallic member901is deformed. Under these circumstances, the conventional art requires a large amount of upset for ensuring a bonding strength.

SUMMARY OF INVENTION

The present invention has been made in view of solving the problems as described above, and an object thereof is to provide a metallic member bonding device allowed to suppress an increase in an amount of upset while ensuring a high bonding strength, and a bonding method therefor.

A metallic member bonding device according to one aspect of the present invention is a bonding device for pressing a first metallic member having a rod shape or a cylindrical shape into a hole portion of a second metallic member having an annular shape to bond the first metallic member and the second metallic member.

The first metallic member, which is one of the members to be bonded, is made of a first metallic material.

The second metallic member, which is the other member to be bonded, is made of a second metallic material different from the first metallic material and has the hole portion with a cross section smaller in size than a cross section of the first metallic member.

Then, the metallic member bonding device according to the present aspect includes a pressurizing unit, a current supply unit, and a deformation suppressing unit.

The pressurizing unit pressurizes the first metallic member toward the hole portion of the second metallic member to press the first metallic member therein.

The current supply unit supplies a welding current between the first metallic member and the second metallic member.

The deformation suppressing unit suppresses deformation of one of the first metallic member and the second metallic member, the one member having a constituent metallic material with at least one of a proof stress and a melting temperature lower than that of the other member, the deformation being in a direction of the cross section crossing a direction of the press-in.

Here, the deformation suppressing unit is provided in a region covering at least a plastic flow range in the press-in direction.

In the metallic member bonding device according to the present aspect, the deformation suppressing unit is provided which suppresses deformation, in the cross section direction, of a member having a constituent metallic material with at least one of a proof stress and a melting temperature lower than that of the other member. Therefore, it is possible to suppress deformation of the member with the lower value after pressing the first metallic member into the hole portion of the second metallic member by the pressurizing unit and starting a current flow.

Additionally, because the deformation suppressing unit is provided in a region covering the plastic flow range, generation and outward discharge of burrs can be effectively suppressed in the region.

Accordingly, at the time of bonding different kinds of metallic members (the first metallic member and the second metallic member) whose constituent metallic materials each have at least one of a proof stress and a melting temperature different from each other, the metallic member bonding device according to the present aspect enables suppression of an increase in an amount of upset while ensuring a high bonding strength.

DESCRIPTION OF EMBODIMENTS

In the following, embodiments of the present invention will be described with reference to the drawings. Embodiments to be described in the following are according to one aspect of the present invention only, and the present invention is not limited by embodiments set forth below except for substantive configuration thereof.

First Embodiment

1. Configuration of Metallic Member Bonding Device1

A configuration of a metallic member bonding device1according to a first embodiment will be described with reference toFIG. 1.

As shown inFIG. 1, the metallic member bonding device1according to the present embodiment includes a base10, a pressurizing unit19, a deformation suppressing unit17, and a welding current supply unit18. The base10is trapezoidal. A second metallic member101is placed on an upper surface10aof the base10. The pressurizing unit19has a welding head11, a pressurizing rod12, and a pressurizing mechanism (not illustrated).

The welding head11is bonded to the pressurizing rod12and can be lowered in a Z-axis direction as indicated by an arrow A1. A first metallic member100is held by the welding head11. Here, the device can be also configured such that, with the first metallic member100set to be placed on the second metallic member101, the welding head11can be lowered to pressurize the first metallic member100.

Although not illustrated, the pressurizing rod12is coupled to the pressurizing mechanism so as to be raised and lowered in the Z-axis direction in conjunction with a drive of the pressurizing mechanism. Specific examples of the pressurizing mechanism include a pneumatic cylinder, a hydraulic cylinder, an electric motor, and the like.

The deformation suppressing unit17has a pair of deformation suppressing heads13and14, pressing rods15and16bonded to the respective deformation suppressing heads13and14, and a pressing mechanism (not illustrated). The deformation suppressing heads13and14are disposed so as to surround an outer circumferential portion of the second metallic member101placed on the upper surface10aof the base10. The outer circumferential portion of the second metallic member101and inner circumferential portions of the deformation suppressing heads13and14are closely in contact with each other approximately without a gap.

The deformation suppressing heads13and14are configured to press the outer circumferential portion of the second metallic member101inwardly in a cross section direction as indicated by arrows A2and A3upon receiving a pressing force via the pressing rods15and16. Although not illustrated, the pressing rods15and16are coupled to the pressing mechanism so as to move forward and backward in an X direction in conjunction with a drive of the pressing mechanism. Specific examples of the pressing mechanism include a pneumatic cylinder, a hydraulic cylinder, an electric motor, and the like.

In the above, the “cross section direction” represents a direction orthogonal to a press-in direction of the first metallic member100into a hole portion101aof the second metallic member101(a plane direction orthogonal to the Z direction). In the present disclosure, this is also the case with other parts.

Here, pressing by the deformation suppressing heads13and14is conducted in synchronization with pressurization of the welding head11. More specifically, at timing (in synchronization with) when a front end of the first metallic member100starts to be pressed into the hole portion101aof the second metallic member101after the welding head11is lowered as indicated by the arrow A1, the deformation suppressing heads13and14start pressing the outer circumferential portion of the second metallic member101as indicated by the arrows A2and A3.

A pressing force and a pressing stroke of the deformation suppressing heads13and14are controlled such that the outer circumferential portion of the second metallic member101is not reduced in diameter by a predetermined amount or more.

The welding current supply unit18supplies a large current between the first metallic member100and the second metallic member101in a short period of time. AlthoughFIG. 1illustrates that wiring is connected directly from the welding current supply unit18to the first metallic member100and the second metallic member101, a wiring mode in practice is not limited thereto. For example, the base10and the welding head11may be formed of a conductive material so that a current is supplied from the welding current supply unit18via the base10and the welding head11.

Specifically, as the welding current supply unit18, a large current supply device can be adopted which includes an electrolytic condenser, a weld transformer, a discharge circuit, and a large current circuit. The welding current supply unit18is a device which once charges the electrolytic condenser with electric energy required for welding and discharges the electric energy to the transformer in a short period of time, thereby supplying a large current between the first metallic member100and the second metallic member101in a short period of time.

2. First Metallic Member100and Second Metallic Member101to be Bonded

Subsequently, description will be made of the first metallic member100and the second metallic member101to be bonded with reference toFIG. 1.

As shown inFIG. 1, the first metallic member100has a solid rod shape. Then, the first metallic member100is disposed so as to have an axis thereof along the Z direction.

A lower end of the first metallic member100in the Z direction, i.e., an outer circumferential surface of a front end side to be pressed into the hole portion101aof the second metallic member101, is a tapered portion100a.

Additionally, the first metallic member100has a cross section diameter larger than a hole diameter of the hole portion101aof the second metallic member101.

A constituent metallic material of the first metallic member100is a metallic material containing iron (Fe), specifically, made of carbon steel. In the present embodiment, S35C is adopted as one example. A yield point (proof stress) of S35C is not less than 305 (N/mm2) and a melting temperature is 1538 (° C.). Additionally, a linear expansion coefficient is 11.7 (×10−6/° C.).

On the other hand, the second metallic member101, which is annular, has the hole portion101awith a diameter smaller than the cross section diameter of the first metallic member100. In the second metallic member101, a press-in side rim of the hole portion101ais a tapered portion101b. A taper angle of the tapered portion101bis approximately the same as a taper angle of the tapered portion100aof the first metallic member100.

The second metallic member101is a metallic material containing aluminum (Al), specifically, made of an aluminum alloy. In the present embodiment, as one example, A5056 (H34) which is an Al—Mg-based aluminum alloy is adopted. A yield point (proof stress) of A5056 (H34) is 230 (N/mm2) and a melting temperature is 568 to 638 (° C.). Additionally, a linear expansion coefficient is 26.3 (×10−6/° C.).

3. Configuration of Deformation Suppressing Unit17

Supplementary description will be made of a configuration of the deformation suppressing unit17provided in the metallic member bonding device1according to the present embodiment with reference toFIG. 2.FIG. 2is a schematic plan view showing the deformation suppressing unit17in a plan view seen from above in the Z direction inFIG. 1.

As shown inFIG. 2, the deformation suppressing heads13and14in the deformation suppressing unit17each have a semi-annular shape. The deformation suppressing head13and the deformation suppressing head14are disposed so as to have end sides thereof opposed to each other.

The second metallic member101with the hole portion101ahas an outer circumferential portion101calong which the inner circumferential surfaces of the deformation suppressing heads13and14are provided approximately without a gap. Between the deformation suppressing heads13and14, which are in contact with the outer circumferential portion101cof the second metallic member101, gaps G1and G2are provided. The gaps G1and G2are minute gaps.

Here, the reason for providing the gaps G1and G2between the deformation suppressing heads13and14in contact with the outer circumferential portion101cof the second metallic member101is to suppress deformation of the second metallic member101even with a dimensional tolerance of the second metallic member101or dimensional tolerances of the deformation suppressing heads13and14.

4. Bonding of First Metallic Member100and Second Metallic Member101Using Metallic Member Bonding Device1

Bonding of the first metallic member100and the second metallic member101using the metallic member bonding device1configured as above is conducted in the following manner.

(i) The first metallic member100is prepared and set to the welding head11. As shown inFIG. 1, in setting the first metallic member100to the welding head11, the first metallic member100is set such that, at a front end outer periphery thereof, the tapered portion100afaces the base10side.

(ii) The second metallic member101is prepared and placed on the upper surface10aof the base10. At this time, the second metallic member101is placed such that the side on which the tapered portion101bis provided at the press-in side rim faces the welding head11side. Additionally, positional adjustment is conducted such that the center of the hole of the hole portion101ain the second metallic member101coincides with an axis of the first metallic member100set to the welding head11.

(iii) The deformation suppressing heads13and14of the deformation suppressing unit17are set to the outer circumferential portion101cof the second metallic member101. At this stage, it is assumed that the deformation suppressing heads13and14are simply set to the outer circumferential portion101cof the second metallic member101so as not to have a gap, and no pressing force is applied inwardly in a radial direction.

(iv) The welding head11is lowered as indicated by the arrow A1.

(v) At a time point when the front end of the first metallic member100and an opening edge facing the hole portion101aof the second metallic member101come into contact with or come close to each other, current supply is started from the welding current supply unit18.

(vi) At a time point when the front end of the first metallic member100starts to be pressed into the hole portion101aof the second metallic member101, along with the above current supply, the deformation suppressing heads13and14are pressed inwardly in the radial direction of the second metallic member101as indicated by the arrows A2and A3. In other words, in synchronization with pressing of the first metallic member100into the hole portion101aof the second metallic member101, a fastening load is applied inwardly in the radial direction of the second metallic member101.

(vii) The first metallic member100is pressed in by a prescribed amount of upset to end the bonding. Then, simultaneously with the completion of the bonding, or a little later, deformation suppressing operation by the deformation suppressing unit17ends.

5. Function Performed by Deformation Suppressing Unit17

Description will be made of a function performed by the deformation suppressing unit17in the metallic member bonding device1with reference toFIG. 3andFIG. 4.FIG. 3is a schematic view schematically showing an appearance of the second metallic member101in a state where the first metallic member100is pressed in and a welding current is supplied.FIG. 4is a schematic sectional view showing the first metallic member100and the second metallic member101being bonded by using the metallic member bonding device1.

As described above, the second metallic member101is made of an aluminum alloy, and thus has both a proof stress and a melting temperature lower than those of carbon steel forming the first metallic member100. Thus, as shown inFIG. 3, a force F1is exerted on the second metallic member101to deform the second metallic member101outwardly in the radial direction. This invites an extension of circumferential lengths of an inner circumferential portion101dand the outer circumferential portion101cof the second metallic member101.

However, in the present embodiment, with the deformation suppressing heads13and14of the deformation suppressing unit17in contact with the outer circumferential portion101c, the second metallic member101is applied a force F2inwardly in the radial direction in synchronization with engagement. Accordingly, in the second metallic member101, an outer diameter D2barely changes and an inner diameter D1also substantially barely changes except for a change due to plastic flow.

As described in the foregoing, in the first metallic member100and the second metallic member101bonded using the metallic member bonding device1provided with the deformation suppressing unit17, burr generation and discharge are suppressed as shown inFIG. 4and generation of such an “unbonded portion” as shown inFIG. 10is also suppressed. Thus, in bonding using the metallic member bonding device1according to the present embodiment, a bonding portion (a diffusion layer102) with a long bonding length LB102can be formed while suppressing an increase in an amount of upset.

Accordingly, in the bonding using the metallic member bonding device1according to the present embodiment, the first metallic member100and the second metallic member101can be bonded with a high bonding strength while suppressing an increase in an amount of upset.

As shown inFIG. 4, in the metallic member bonding device1according to the present embodiment, the deformation suppressing unit17has a height H13of the deformation suppressing heads13and14(inFIG. 4, only the deformation suppressing head13is illustrated) in the Z direction set to be equal to or larger than a height of the second metallic member101in the Z direction. In other words, a lower surface13bof the deformation suppressing head13,14is set to make contact with the upper surface10aof the base10, and an upper surface13ais set to be flush with an upper surface of the second metallic member101in the Z direction or located higher than the upper surface.

By setting a size and arrangement of the deformation suppressing heads13and14in a manner as described above, a fastening load can be applied to the second metallic member101within a range covering a range of plastic flow at the time of bonding (approximately the same range where the diffusion layer102is formed) in the Z direction. This enables deformation of the second metallic member101to be reliably suppressed in a direction to increase the radius within a range where plastic flow occurs at the time of bonding, so that generation and outward discharge of burrs are suppressed.

The metallic member bonding device1is provided with the deformation suppressing unit17which suppresses deformation of the outer circumferential portion101cof the second metallic member101in a direction to increase the radius, the second metallic member101having a constituent material with both a proof stress and a melting temperature lower than those of the first metallic member100. Therefore, it is possible to suppress deformation of the second metallic member101in the direction to increase the radius after pressing the first metallic member100into the hole portion101aof the second metallic member101and starting a current flow.

Additionally, since the deformation suppressing unit17is provided so as to press a region covering a plastic flow range, generation and outward discharge of burrs at the time of bonding can be effectively suppressed.

Accordingly, when bonding the first metallic member100made of carbon steel and the second metallic member101made of an aluminum alloy, the metallic member bonding device1according to the present embodiment enables an increase in an amount of upset to be suppressed while ensuring a high bonding strength.

Additionally, since the metallic member bonding device1applies a fastening load by the deformation suppressing unit17in synchronization with pressing of the first metallic member100into the hole portion101aby lowering of the welding head11, a load for suppressing deformation can be applied at appropriate timing. It is therefore possible to efficiently suppress an increase in an amount of upset while ensuring a high bonding strength.

Additionally, the deformation suppressing unit17in the metallic member bonding device1has two deformation suppressing heads13and14. This enables less non-uniform pressing and enables deformation of the second metallic member101in the cross section direction to be uniformly suppressed in a direction to increase the radius.

Second Embodiment

1. Configuration of Metallic Member Bonding Device2

A configuration of a metallic member bonding device2according to a second embodiment will be described with reference toFIG. 5.FIG. 5is a schematic sectional view showing the configuration of the metallic member bonding device2, in which illustration of a part of the configuration is omitted. Additionally, inFIG. 5, the same reference numerals are assigned to parts with the same configurations as those of the metallic member bonding device1according to the first embodiment to omit detailed description thereof in the following.

As shown inFIG. 5, in the metallic member bonding device2, a deformation suppressing unit20is provided within a tube of a tubular second metallic member104. The deformation suppressing unit20is designed to apply a pressing force to an inner circumferential portion104bof the second metallic member104outwardly in a radial direction thereof.

A lower end of the second metallic member104in a Z direction, i.e., an outer circumferential surface of a front end side to be pressed into a hole portion103aof the first metallic member103, is a tapered portion104a, which arrangement is the same as the first metallic member100of the first embodiment.

On the other hand, in the metallic member bonding device2according to the present embodiment, no deformation suppressing unit is provided for applying a fastening load to an outer circumferential portion of the first metallic member103. Although not illustrated, there is provided a positioning device for the first metallic member103to suppress a positional displacement on the base10.

A press-in side rim of the hole portion103aof the first metallic member103is a tapered portion103b. A taper angle of the tapered portion103bis approximately the same as a taper angle of the tapered portion104aof the second metallic member104. Additionally, a hole diameter of the hole portion103aof the first metallic member103is a little larger than an outer diameter of the second metallic member104.

2. Each Constituent Metallic Material of First Metallic Member103and Second Metallic Member104

A constituent metallic material of the first metallic member103is a metallic material containing iron (Fe), specifically, made of carbon steel. Also in the present embodiment, S35C is adopted as one example similarly to the first embodiment. A yield point (proof stress) of S35C is not less than 305 (N/mm2) and a melting temperature is 1538 (° C.). Additionally, a linear expansion coefficient is 11.7 (×10−6/° C.).

On the other hand, a constituent metallic material of the second metallic member104is a metallic material containing aluminum (Al), specifically, made of an aluminum alloy. Also in the present embodiment, as one example, A5056 (H34) is adopted which is an Al—Mg-based aluminum alloy similarly to the first embodiment. A yield point (proof stress) of A5056 (H34) is 230 (N/mm2) and a melting temperature is 568 to 638 (° C.). Additionally, a linear expansion coefficient is 26.3 (×10−6/° C.).

3. Configuration of Deformation Suppressing Unit20

Supplementary description will be made of a configuration of the deformation suppressing unit20provided in the metallic member bonding device2according to the present embodiment with reference toFIG. 6.FIG. 6is a schematic plan view showing the deformation suppressing unit20in a virtual plan view seen from above in the Z direction inFIG. 5.

As shown inFIG. 6, the deformation suppressing unit20has six deformation suppressing heads21to26. Additionally, although not illustrated, the deformation suppressing unit20has a pressing mechanism for causing the respective deformation suppressing heads21to26to move forward and backward in the radial direction.

Each of the deformation suppressing heads21to26has a fan-shape obtained by dividing a circle into six. Each of the deformation suppressing heads21to26is designed such that each outer circumferential surface makes contact with the inner circumferential portion104bof the second metallic member104approximately without a gap when expanding in the radial direction.

The deformation suppressing unit20provided in the metallic member bonding device2according to the present embodiment has the same mechanism as that of a so-called inside diameter gripping collet chuck.

Also during driving of the metallic member bonding device2according to the present embodiment, the deformation suppressing unit20applies a load to the inner circumferential portion104bof the second metallic member104in a direction to increase the radius in synchronization with pressing of the second metallic member104into the hole portion103aof the first metallic member103by lowering of the welding head11in the pressurizing unit19.

4. State of Bonding Between First Metallic Member103and Second Metallic Member104

In the first metallic member103and the second metallic member104bonded using the metallic member bonding device2provided with the deformation suppressing unit20, as shown inFIG. 7, generation and outward discharge of burrs are suppressed and generation of such an “unbonded portion” as shown inFIG. 10is also suppressed. Thus, in bonding using the metallic member bonding device2according to the present embodiment, a bonding portion (a diffusion layer105) with a long bonding length LB105can be formed while suppressing an increase in an amount of upset.

Accordingly, also in the bonding using the metallic member bonding device2according to the present embodiment, the first metallic member103and the second metallic member104can be bonded with a high bonding strength while suppressing an increase in an amount of upset.

As illustrated inFIG. 7, in the metallic member bonding device2according to the present embodiment, a height H23of the deformation suppressing heads21to26(inFIG. 7, only the deformation suppressing head23is illustrated) in the Z direction in the deformation suppressing unit20is set to cover a range of plastic flow (approximately the same range where the diffusion layer105is formed) at the time of bonding. In other words, a lower surface23bof each of the deformation suppressing heads21to26is set to be approximately flush with the lower end surface of the second metallic member104in the Z direction, and an upper surface23ais set to be above, in the Z direction, a planned region in which the diffusion layer105is to be formed.

By setting a size and arrangement of the deformation suppressing heads21to26in a manner as described above, a load can be applied to the second metallic member104outwardly in the radial direction within a range covering a range of plastic flow (approximately the same range where the diffusion layer105is formed) at the time of bonding in the Z direction. This enables deformation of the second metallic member104to be reliably suppressed in a direction to reduce the radius within a range where plastic flow occurs at the time of bonding, so that generation and outward discharge of burrs are suppressed.

The metallic member bonding device2is provided with the deformation suppressing unit20which suppresses deformation of the inner circumferential portion104bof the second metallic member104in a direction to reduce the radius, the second metallic member104having a constituent material with both a proof stress and a melting temperature lower than those of the first metallic member103. Therefore, it is possible to suppress deformation of the second metallic member104in the direction to reduce the radius after pressing the second metallic member104into the hole portion103aof the first metallic member103and starting a current flow.

Additionally, since the deformation suppressing unit20is provided so as to press a region covering a plastic flow range, generation and outward discharge of burrs at the time of bonding can be effectively suppressed.

Accordingly, when bonding the first metallic member103made of carbon steel and the second metallic member104made of an aluminum alloy, the metallic member bonding device2according to the present embodiment also enables an increase in an amount of upset to be suppressed while ensuring a high bonding strength.

Additionally, since the metallic member bonding device2according to the present embodiment applies a load outwardly in the radial direction by the deformation suppressing unit20in synchronization with pressing of the second metallic member104into the hole portion103aby lowering of the welding head11in the pressurizing unit19, a load for suppressing deformation can be applied at appropriate timing. It is therefore possible to efficiently suppress an increase in an amount of upset while ensuring a high bonding strength.

Additionally, the deformation suppressing unit20in the metallic member bonding device2has the six deformation suppressing heads21to26. This enables less non-uniform pressing and enables deformation of the second metallic member104in the cross section direction to be uniformly suppressed in a direction to reduce the radius.

Third Embodiment

A configuration of a metallic member bonding device according to a third embodiment will be described with reference toFIG. 8.FIG. 8shows a part of a configuration of a deformation suppressing unit30as extracted among configurations of the metallic member bonding device according to the present embodiment. Respective configurations whose illustration is omitted are the same as those of the metallic member bonding device1according to the first embodiment.

As shown inFIG. 8, the deformation suppressing unit30provided in the metallic member bonding device according to the present embodiment has three deformation suppressing heads31to33, and pressing rods34to36connected to the respective deformation suppressing heads31to33. Additionally, although not illustrated, the deformation suppressing unit30has a pressing mechanism connected to the pressing rods34to36to cause the respective deformation suppressing heads31to33to move forward or backward in a radial direction.

Each of the deformation suppressing heads31to33has a planar shape obtained by dividing a circle into three. The deformation suppressing heads31to33are disposed so as to have end sides thereof opposed to each other.

A second metallic member101with a hole portion101ahas an outer circumferential portion101calong which inner circumferential surfaces of the deformation suppressing heads31to33fit approximately without a gap. The deformation suppressing heads31to33are configured so as to have gaps G3, G4, and G5therebetween in a state, as indicated by arrows A4to A6, where the deformation suppressing heads31to33are moved forward inwardly in the radial direction so as to make contact with the outer circumferential portion101cof the second metallic member101. The gaps G3, G4, and G5are minute gaps.

Also in the present embodiment, provision of the gaps G3, G4, and G5allows deformation of the second metallic member101to be suppressed even with a dimensional tolerance of the second metallic member101or dimensional tolerances of the deformation suppressing heads31to33similarly to the above.

Also in the metallic member bonding device having the deformation suppressing unit30configured as above, the same effect as that of the metallic member bonding device1according to the first embodiment can be obtained.

Fourth Embodiment

A configuration of a metallic member bonding device according to a fourth embodiment will be described with reference toFIG. 9.FIG. 9shows a part of a configuration of a deformation suppressing unit40as extracted among configurations of the metallic member bonding device according to the present embodiment.

First, while in the first to third embodiments, a member having a round or annular cross section is adopted as a member to be bonded, in the present embodiment, a second metallic member106having a square annular cross section is one of the members to be bonded as shown inFIG. 9.

Although not illustrated, the other member to be bonded is a rod-shaped or cylindrical metallic member having a square cross section corresponding to a shape of a hole portion106ain the second metallic member106.

As shown inFIG. 9, the deformation suppressing unit40of the metallic member bonding device according to the present embodiment includes four deformation suppressing heads41to44and four pressing heads45to48. The four deformation suppressing heads41to44are configured to be able to make contact with four outer circumferential portions106cto106fin the second metallic member106each without a gap. Although not illustrated, the four pressing heads45to48are connected to a pressing mechanism, and are capable of inwardly applying a fastening load to the second metallic member106as indicated by arrows A7to A10in synchronization with pressing of the first metallic member into the hole portion106aby a pressurizing unit19.

Also in the metallic member bonding device having the deformation suppressing unit40configured as above, the same effect as that of the metallic member bonding device1according to the first embodiment can be obtained.

Modification

Although in the first to fourth embodiments, a member made of a material containing Al (an Al alloy) and a member made of a material containing Fe (carbon steel) are adopted as the members to be bonded, the present invention is not limited thereto. In the present invention, the effect can be obtained by providing such a deformation suppressing unit as described above for bonding between members made of materials each having at least one of a proof stress and a melting temperature different from each other.

The present invention is also applicable, for example, to bonding between a member made of a material containing magnesium (Mg) (e.g., a Mg alloy) and a member made of a material containing Al (e.g., an Al alloy), and to bonding between a member made of a material containing Mg (e.g., a Mg alloy) and a member made of a material containing Fe (e.g., carbon steel). Also in these cases, a deformation suppressing unit can be provided in consideration of at least either one of a proof stress and a melting temperature of a material forming the member.

When an MDC1D is used as a Mg alloy, for example, a yield point (proof stress) is 160 (N/mm2) and a melting temperature is 470 to 595 (° C.). Additionally, a linear expansion coefficient is 27.0 (×10−6/° C.). A relation can be taken into consideration between these physical properties and a material forming a member as a bonding target.

In the second embodiment, the deformation suppressing unit20is provided for the second metallic member104so as to suppress the second metallic member104from having a reduced diameter at the time of bonding with the first metallic member103. In the present invention, for example, a deformation suppressing unit may be further provided for the first metallic member103in the second embodiment. This is because when a welding current is passed, temperatures of the members103and104are increased and the members103and104tend to expand. In this case, the diameter of the first metallic member103made of carbon steel and having an annular shape is likely to be increased. Suppressing the increase in diameter will be effective in suppressing generation and outward discharge of burrs. For a metallic member to be bonded, even when a constituent material thereof is other than those described above, a deformation suppressing unit that obtains the same effect can be configured by taking into consideration a linear expansion coefficient together with a proof stress and a melting temperature of a constituent material of each member.

While in the first to fourth embodiments, one example is shown as a shape of the members100,101,103,104, and106to be bonded, the present invention is not limited thereto. For example, an elongate annular member or a member having an outer circumference of a triangle, or a polygon more than a pentagon in a plan view can be a member to be bonded. In this case, the same effect as described above can be obtained by providing a deformation suppressing head corresponding to a shape of each of the outer circumferential portions.

In the first to fourth embodiments, it is assumed that deformation of the second metallic members101,104, and106is suppressed by providing the deformation suppressing units17,20,30, and40. The deformation suppressing units17,20,30, and40in these embodiments are assumed to have a function of suppressing deformation of the second metallic members101,104, and106in a direction of a cross section.

However, the present invention is not limited thereto. For example, in a state where a welding current is passed and a metallic member having a lower melting temperature is partly softened, the softened metallic member may be deformed in the cross section direction toward the other metallic member to be bonded. Such a configuration has an advantage in suppressing a reduction in density of a plastically fluidized region in the cross section direction, thereby ensuring a high bonding strength.

Although in the first, third, and fourth embodiments, a fastening load is applied to the outer circumferential portions101c,106c,106d,106e, and106fof the second metallic members101and106, the present invention is not limited thereto. For example, an upper surface of an outer edge portion of the second metallic member101in the Z direction shown inFIG. 1may be pressed against the base10to suppress deformation of the second metallic member101in the radial direction by a frictional force.

Although the second metallic member101is placed on the upper surface10aof the base10in the first embodiment and the first metallic member103is placed on the same in the second embodiment, the present invention is not limited thereto. For example, a second welding head may be provided opposed to the welding head11to grip the second metallic member101and the first metallic member103, so as to rise upwardly in the Z direction at the time of welding.

While in the first to third embodiments, the deformation suppressing heads13and14,21to26, and31to33are configured to be able to move forward or backward only in the radial direction, the present invention is not limited thereto. For example, the respective deformation suppressing heads can be configured to spirally rotate to increase or decrease in a diameter.

Additionally, although the two deformation suppressing heads13and14are provided in the first embodiment, the six deformation suppressing heads21to26are provided in the second embodiment, the three deformation suppressing heads31to33are provided in the third embodiment, and the four deformation suppressing heads41to44are provided in the fourth embodiment, the present invention is not limited thereto. For example, an integrally formed annular deformation suppressing head may be prepared inFIG. 1and may be brought into close contact with the outer circumferential portion of the annular second metallic member101.

Additionally, as described above, the size of the deformation suppressing head in the metallic member press-in direction is not limited to those of the above respective embodiments as long as the size is within a range of plastic flow of a metallic member to be bonded.

Additionally, while in the first and second embodiments, the metallic members100,101,103, and104to be bonded are provided with the tapered portions100a,101b,103b, and104a, the present invention may not necessarily require a tapered portion.

Conclusion

The metallic member bonding device according to one aspect of the present invention is a bonding device for pressing a first metallic member having a rod shape or a cylindrical shape into a hole portion of a second metallic member having an annular shape to bond the first metallic member and the second metallic member.

The first metallic member, which is one of the members to be bonded, is made of a first metallic material.

The second metallic member, which is the other member to be bonded, is made of a second metallic material different from the first metallic material and has the hole portion with a cross section smaller in size than a cross section of the first metallic member.

Then, the metallic member bonding device according to the present aspect includes a pressurizing unit, a current supply unit, and a deformation suppressing unit.

The pressurizing unit pressurizes the first metallic member toward the hole portion of the second metallic member to press the first metallic member therein.

The current supply unit supplies a welding current between the first metallic member and the second metallic member.

The deformation suppressing unit suppresses deformation of one of the first metallic member and the second metallic member, the one member having a constituent metallic material with at least one of a proof stress and a melting temperature lower than that of the other member, the deformation being in a direction of the cross section crossing a direction of the press-in.

Here, the deformation suppressing unit is provided in a region covering at least a plastic flow range in the press-in direction.

In the metallic member bonding device according to the present aspect, the deformation suppressing unit is provided which suppresses deformation, in the cross section direction, of a member having a constituent metallic material with at least one of a proof stress and a melting temperature lower than that of the other member. Therefore, it is possible to suppress deformation of the member with the lower value after pressing the first metallic member into the hole portion of the second metallic member by the pressurizing unit and starting a current flow.

Additionally, because the deformation suppressing unit is provided in a region covering the plastic flow range, generation and outward discharge of burrs can be effectively suppressed in the region.

Accordingly, at the time of bonding different kinds of metallic members (the first metallic member and the second metallic member) whose constituent metallic materials each have at least one of a proof stress and a melting temperature different from each other, the metallic member bonding device according to the present aspect enables suppression of an increase in an amount of upset while ensuring a high bonding strength.

A “range of plastic flow” can be experimentally or experientially set on the basis of physical properties, bonding conditions, environmental conditions, and the like of the first metallic material and the second metallic material, respectively.

Additionally, as the current supply unit, a current supply device for a known metallic member bonding device (condenser weld device) can be adopted. Specifically, the device includes an electrolytic condenser, a weld transformer, a discharge circuit, and a large current circuit, and once charges the electrolytic condenser with electric energy required for welding and discharges the electric energy to the transformer in a short period of time, thereby supplying a large current between the first metallic member and the second metallic member in a short period of time.

In the metallic member bonding device according to another aspect of the present invention, in the above configuration, the second metallic material has a proof stress and a melting temperature lower than those of the first metallic material, and the deformation suppressing unit applies a fastening load to the second metallic member from an outer circumferential portion of the second metallic member inwardly in the cross section direction.

As described above, in a case where the proof stress and the melting temperature of the second metallic material are lower than those of the first metallic material, when a current flow is started with pressure applied by the pressurizing unit, both inner and outer peripheries of the second metallic member tend to increase in length due to a temperature rise and an outward stress in the cross section direction. In other words, the second metallic member tends to increase in diameter.

However, in the metallic member bonding device according to the present aspect, since the second metallic member is fastened inwardly in the cross section direction from the outer circumferential portion thereof by the deformation suppressing unit, outward expansion of the second metallic member can be suppressed.

Accordingly, in the metallic member bonding device according to the present aspect, even when the second metallic member is formed of a material having relatively low proof stress and melting temperature, an increase in an amount of upset can be suppressed while ensuring a high bonding strength.

In the metallic member bonding device according to a further aspect the present invention, in the above configuration, application of the fastening load to the deformation suppressing unit is conducted in synchronization with pressing of the first metallic member into the hole portion of the second metallic member by the pressurizing unit.

In the metallic member bonding device according to the present aspect, since application of a fastening load and press-in can be conducted in synchronization with each other, a load for suppressing deformation can be applied at appropriate timing. It is therefore possible to efficiently suppress an increase in an amount of upset while ensuring a high bonding strength.

In the metallic member bonding device according to a still further aspect of the present invention, in the above configuration, the deformation suppressing unit has a plurality of deformation suppressing heads disposed in a state of surrounding the outer circumferential portion of the second metallic member, and has a pressing mechanism which presses each of the plurality of deformation suppressing heads inwardly in the cross section direction.

The metallic member bonding device according to the present aspect is assumed to have, as a specific configuration of the deformation suppressing unit, the plurality of deformation suppressing heads and the pressing mechanism which presses the plurality of deformation suppressing heads. This enables deformation of the second metallic member to be suppressed without using a complicated mechanism.

Additionally, since the outer circumferential portion of the second metallic member is pressed using the plurality of deformation suppressing heads, less non-uniform pressing is allowed to enable outward expansion of the second metallic member in the cross section direction to be uniformly suppressed.

As specific examples of the “pressing mechanism”, a pneumatic cylinder, a hydraulic cylinder, an electric motor, and the like can be adopted or manual pressing is also possible via a linking mechanism or the like (more specifically, e.g., a configuration using a collet chuck).

In the metallic member bonding device according to a still further aspect of the present invention, in the above configuration, the second metallic material is a material containing aluminum and the first metallic material is a material containing iron.

In the metallic member bonding device according to the present aspect, also when bonding an aluminum-based material (a material containing aluminum) and an iron-based material (a material containing iron) having proof stresses and melting temperatures different from each other, an increase in an amount of upset can be suppressed while ensuring a high bonding strength.

In the metallic member bonding device according to a still further aspect of the present invention, in the above configuration, the first metallic material has a proof stress and a melting temperature lower than those of the second metallic material, the first metallic member has a cylindrical shape, and the deformation suppressing unit applies a load to the first metallic member outwardly in the cross section direction from an inner circumferential portion of the first metallic member.

In the metallic member bonding device according to the present aspect, even when a proof stress and a melting temperature of the first metallic material forming the first metallic member are lower than those of the second metallic material forming the second metallic member, an increase in an amount of upset can be suppressed while ensuring a bonding strength similarly to the above.

In the metallic member bonding device according to a still further aspect of the present invention, in the above configuration, application of the load by the deformation suppressing unit is conducted in synchronization with pressing of the first metallic member into the hole portion of the second metallic member by the pressurizing unit.

Also in the metallic member bonding device according to the present aspect, by conducting application of a load by the deformation suppressing unit and press-in in synchronization with each other, a load for suppressing deformation can be applied at appropriate timing. It is therefore possible to efficiently suppress an increase in an amount of upset while ensuring a high bonding strength.

The metallic member bonding method according to one aspect of the present invention is a method of pressing a first metallic member having a rod shape or a cylindrical shape into a hole portion of a second metallic member having an annular shape to bond the first metallic member and the second metallic member, the method including:

(i) a first metallic member preparation step of preparing the first metallic member made of a first metallic material;

(ii) a second metallic member preparation step of preparing the second metallic member made of a second metallic material different from the first metallic material and having the hole portion with a cross section smaller in size than a cross section of the first metallic member;

(iii) a pressurization step of pressurizing the first metallic member toward the hole portion of the second metallic member to press the first metallic member therein;

(iv) a current supply step of supplying a welding current between the first metallic member and the second metallic member; and

(v) a deformation suppressing step of suppressing deformation, in a direction of the cross section, of one of the first metallic member and the second metallic member, the one member having a constituent metallic material with at least one of a proof stress and a melting temperature lower than the other member.

The metallic member bonding method according to the present aspect, deformation is suppressed in the press-in direction within a region covering at least a plastic flow range in the deformation suppressing step.

In the metallic member bonding method according to the present aspect, (v) the deformation suppressing step of suppressing deformation in the cross section direction is conducted for the member having a constituent metallic material with at least one of a proof stress and a melting temperature lower than that of the other member. Therefore, it is possible to suppress deformation of the member with the lower value after pressing the first metallic member into the hole portion of the second metallic member in (iii) the pressurization step and starting a current flow.

Additionally, since in (v) the deformation suppressing step, deformation is suppressed within a region covering a plastic flow range, generation and outward discharge of burrs can be effectively suppressed in the region.

Accordingly, the metallic member bonding method according to the present aspect enables, at the time of bonding different kinds of metallic members (the first metallic member and the second metallic member) having constituent metallic materials with at least one of a proof stress and a melting temperature different from each other, suppression of an increase in an amount of upset while ensuring a high bonding strength.

In the metallic member bonding method according to another aspect of the present invention, with the above method, the second metallic material has a proof stress and a melting temperature lower than those of the first metallic material, and in the deformation suppressing step, a fastening load is applied to the second metallic member from an outer circumferential portion of the second metallic member inwardly in the cross section direction.

As described above, in a case where the second metallic material has a proof stress and a melting temperature lower than those of the first metallic material, when a current flow is started while pressure is applied in the pressurization step, both inner and outer peripheries of the second metallic member tend to be increased in length due to a temperature rise and an outward stress in the cross section direction. In other words, a ring of the second metallic member tends to increase in diameter.

However, in the metallic member bonding method according to the present aspect, since the second metallic member is fastened from the outer circumferential portion thereof inwardly in the cross section direction in (v) the deformation suppressing step, outward expansion (an increase in the radius) of the second metallic member can be suppressed.

Accordingly, in the metallic member bonding method according to the present aspect, even when the second metallic member is formed of a material having relatively low proof stress and melting temperature, an increase in an amount of upset can be suppressed while ensuring a high bonding strength.

In the metallic member bonding method according to a further aspect of the present invention, with the above method, application of the fastening load in the deformation suppressing step is conducted in synchronization with pressing of the first metallic member into the hole portion of the second metallic member in the pressurization step.

In the metallic member bonding method according to the present aspect, by conducting application of a fastening load and press-in in synchronization with each other, a load for suppressing deformation can be applied at appropriate timing. It is therefore possible to efficiently suppress an increase in an amount of upset while ensuring a high bonding strength.

In the metallic member bonding method according to a still further aspect of the present invention, with the above method, in the deformation suppressing step, a plurality of deformation suppressing heads disposed in a state of surrounding the outer circumferential portion of the second metallic member is pressed inwardly in the cross section direction by a pressing mechanism connected to each of the plurality of deformation suppressing heads.

The metallic member bonding method according to the present aspect is assumed to have, as a specific method for conducting (v) the deformation suppressing step, the plurality of deformation suppressing heads pressed by the pressing mechanism. This enables deformation of the second metallic member to be suppressed while suppressing variation of a pressing force to be applied in each region of the outer circumferential portion.

Additionally, since the outer circumferential portion of the second metallic member is pressed using the plurality of deformation suppressing heads, less non-uniform pressing is allowed to enable outward expansion (an increase in the radius) of the second metallic member in the cross section direction to be uniformly suppressed.

The foregoing is also the case with specific examples of the pressing mechanism.

In the metallic member bonding method according to a still further aspect of the present invention, with the above method, the second metallic material is a material containing aluminum and the first metallic material is a material containing iron.

In the metallic member bonding method according to the present aspect, also when bonding an aluminum-based material (a material containing aluminum) and an iron-based material (a material containing iron) having proof stresses and melting temperatures different from each other, an increase in an amount of upset can be suppressed while ensuring a high bonding strength.

This application is based on Japanese Patent application No. 2016-165901 filed in Japan Patent Office on Aug. 26, 2016, the contents of which are hereby incorporated by reference.