Manufacturing method of supporting structure for vehicle

A manufacturing method of a supporting structure for vehicle has steps of preparing a casting mold having: a first and a second casting mold, which are matched to each other at casting, and has forming faces which form at least sides of first and second fixing portions and the connecting portion and a third casting mold having a forming face which forms a fixing face of the second fixing portion and a protruding body which forms a recess hole penetrating to an interior of the connecting portion from the fixing face of the second fixing portion; matching the third casting mold together with the first and the second casting mold so as to form a cavity for integrally forming the first fixing portion, the second fixing portion and the connecting portion in the casting mold; and pouring molten metal into the cavity so as to mold the supporting structure.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S. § 119 to application Ser. No. JP2005301922 filed on Oct. 17, 2005, the contents of which are incorporated by reference in their entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a manufacturing method of a supporting structure for vehicle. More particularly, the present invention relates to a manufacturing method of a supporting structure for vehicle characterized in that the supporting structure itself is plastically deformed when a load not less than a setting load is given to the supporting structure so that an impact force impressed upon the supporting structure can be relaxed.

2. Description of Related Art

In a supporting structure for supporting and fixing an engine, transmission, differential gear and so forth, a mechanism is provided which absorbs and relaxes impact energy by the plastic deformation of the supporting structure itself when a load not less than a predetermined value is given by a collision to an object to be supported such as an engine attached to the supporting structure.

For example, Japanese Patent Unexamined Publication JP-A-2002-2310 discloses a bracket used for supporting a power plant which includes a flange portion, on the side of which a notch groove having a V-shaped cross section is formed, and when a load not less than a predetermined value is given, the flange portion is broken from a starting point of the notch groove so that an impact force given to the bracket can be relaxed.

Japanese Patent Unexamined Publication JP-A-2002-127762 discloses an engine mount having a notch portion which becomes a starting point of the plastic deformation or destruction when a load not less than a predetermined value is given to the engine supporting structure.

A supporting structure, which absorbs and relaxes impact energy by the plastic deformation of the supporting structure when a load not less than a predetermined value is given to an object to be supported such as an engine, transmission and differential gear, is formed into various shapes according to a type of the object to be supported and an attaching position. Further, the proof stress, at which the plastic deformation of the supporting structure is made, is variously changed. Concerning the method of forming such various supporting structures and portions which allow the supporting structures to be plastically deformed, when machining such as cutting is employed, the machining work becomes complicated and the manufacturing cost is raised.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a manufacturing method of a supporting structure for vehicle characterized in that it is possible to inexpensively manufacture a supporting structure for absorbing and relaxing impact energy given to an object to be supported when the supporting structure itself is allowed to be deformed, and the supporting structure for vehicle can be surely plastically deformed when a predetermined setting load is given to the supporting structure so that impact energy acting on the object to be supported can be accurately absorbed and relaxed.

In order to accomplish the above object, the present invention has the following constitution.

The present invention provides a manufacturing method of a supporting structure for vehicle, the supporting structure for vehicle including:

a first fixing portion to which an object to be supported is fixed;

a second fixing portion which is fixed to a vehicle body; and

a connecting portion for connecting the first fixing portion with the second fixing portion, wherein

when a load not less than a predetermined value is given to the object to be supported, the connecting portion is plastically deformed by the load,

the manufacturing method comprising:

preparing a casting mold comprising:a first and a second casting mold, which are matched to each other at the time of casting, and comprises forming faces which form at least sides of the first fixing portion, the second fixing portion and the connecting portion; anda third casting mold comprising:a forming face which forms a fixing face of the second fixing portion; anda protruding body which forms a recess hole penetrating to an interior of the connecting portion from the fixing face of the second fixing portion;

matching the third casting mold together with the first and the second casting mold so as to form a cavity for integrally forming the first fixing portion, the second fixing portion and the connecting portion in the casting mold; and

pouring molten metal into the cavity so as to mold the supporting structure.

Further, in the manufacturing method of the supporting structure for vehicle, by using the casting mold in which:

the first fixing portion of the supporting structure is formed so that a longitudinal direction of the first fixing portion agrees with a direction in which the load acts on the object to be supported; and

the first casting mold and the second casting mold are used in such a manner that a face direction of matching the first casting mold and the second casting mold is parallel with the longitudinal direction of the first fixing portion,

the supporting structure can be manufactured with the casting mold which can be simply manufactured.

Furthermore, in the manufacturing method of the supporting structure for vehicle, by using the casting mold in which:

in the first and the second casting molds, the forming face, which forms the connecting portion and is provided at least one of the first and second casting molds, is formed such that:

an interval between the forming faces which forms a side portion of the connecting portion, of which face direction is perpendicular to a loading direction, is smaller than an interval between the forming faces which forms a side portion of the connecting portion, of which face direction is parallel to the loading direction,

it becomes easy to manufacture a supporting structure which can be easily plastically deformed in the loading direction.

Further, in the manufacturing method of the supporting structure for vehicle, by using the casing molds in which:

in the first and the second casting molds, among the forming faces which forms the connecting portion provided at least one of the first and second casting molds, on the forming face which forms a side portion of which face direction is perpendicular to the loading direction, a protrusion which forms a groove on an outer face of the side portion is provided,

it is possible to manufacture a supporting structure, the proof stress, at which the connecting portion is plastically deformed, can be appropriately adjusted.

Furthermore, in the manufacturing method of a supporting structure for vehicle, by using the casting mold in which:

in the first and the second casting molds, among the forming faces which forms the connecting portion provided at least one of the first and second casting molds, on the forming face which forms a side portion of which face direction is parallel to the loading direction, a protrusion which forms a recessed portion on an outer face of the side portion is provided,

it is possible to manufacture a supporting structure by appropriately adjusting the proof stress, at which the connecting portion is plastically deformed, when the cross-sectional shape of the connecting portion or the wall thickness of the connecting portion is appropriately.

According to the manufacturing method of a supporting structure for vehicle of the present invention, the supporting structure having the first fixing portion, the second fixing portion and the connecting portion is manufactured by a casting method in which a casting mold is used. Therefore, the supporting structure can be easily manufactured by appropriately making a design so that the connecting portion of the supporting structure can be plastically deformed when a load is given to it. When the third casting mold is provided with a protruding body for lightening the inside of the connecting portion, it is possible to manufacture a supporting structure in which the proof stress of the connecting portion, at which the connecting portion is plastically deformed, can be appropriately set.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the accompanying drawings, the preferred embodiments of the present invention will be explained in detail as follows.

First Embodiment

FIG. 1is a view showing an example of a supporting structure for vehicle manufactured by the method of the present invention. In this view, an action of the supporting structure for vehicle is also shown. In the view, a supporting structure10includes: a first fixing portion12to which an object to be supported is fixed; a second fixing portion14fixed to a support portion6provided on the vehicle side; and a connecting portion16for integrally connecting the first fixing portion12with the second fixing portion14. From a fixing face of the second fixing portion14to the connecting portion16, a recess hole18, which is open on the fixing face, is provided. Therefore, since a thin wall thickness portion is formed in the connecting portion16, when a load of not less than a predetermined value is given to the object to be supported, the connecting portion16is plastically deformed and an impact can be absorbed.

InFIG. 1A, a loading direction of the object5to be supported is shown by an arrow. A first fixing portion12of the supporting structure10is fixed to the object5to be supported so that the longitudinal direction of the first fixing portion12can agree with the loading direction of the object5to be supported. According to the state of collision of a vehicle, a load can be given to the object to be supported in various directions. For example, the loading direction shown inFIG. 1Ais estimated to be a loading direction in the case where a vehicle comes to a head-on collision with another one.

FIG. 1Ashows a usual state in which the object5to be supported is supported by the supporting structure10.FIG. 1Bshows a state in which the object5to be supported is given a load not less than a setting value and the supporting structure10is plastically deformed as if it fell down in the loading direction. When the supporting structure10is plastically deformed, impact energy acting on the object5to be supported can be absorbed.

FIGS. 2A and 2Bare sectional views showing the supporting structure10illustrated inFIG. 1.FIG. 2cis a plan view showing the supporting structure10illustrated inFIG. 1.FIG. 2Ais a sectional view taken on line A-A inFIG. 2C(plan view).FIG. 2Bis a sectional view taken on line B-B inFIG. 2C. As shown inFIG. 2A, a front shape of the supporting structure10is formed into an H-shape. As shown inFIG. 2B, a side shape of the supporting structure10is formed into a step-shape, the width of which is gradually increased from the first fixing portion12to the second fixing portion14.

As shown inFIG. 2C(Concerning the connecting portion16, a cross-section is shown inFIG. 2C.), a plan shape of the supporting structure10is formed in such a manner that the first fixing portion12is formed into a rectangle and the second fixing portion14is formed into a square, the length of one side of which is equal to the length in the longitudinal direction of the first fixing portion12. The connecting portion16to connect the first fixing portion12with the second fixing portion14is formed into a constricted shape which is constricted in the longitudinal direction of the first fixing portion12. The connecting portion16is a little protruded in the width direction of the first fixing portion12as compared with the width of the first fixing portion12.

A recess hole18, which is formed in the second fixing portion14and the connecting portion16, is open onto the fixing face side of the second fixing portion14and formed into a shape which extends to a portion close to the connecting portion of the connecting portion16with the first fixing portion12. In the present embodiment, an inner face shape of the recess hole18is formed so that the wall thickness of the side portion16a(shown inFIG. 2A) of the connecting portion16perpendicular to the longitudinal direction of the first fixing portion12can be smaller than the wall thickness of the side portion16b(shown inFIG. 2B) parallel to the longitudinal direction of the first fixing portion12. In this connection, the side portion16aperpendicular to the longitudinal direction of the first fixing portion12of the connecting portion16is a pair of side portions of the connecting portion16, the face directions of the outside of which are perpendicular to the longitudinal direction of the first fixing portion12. The side portion16bparallel with the longitudinal direction of the first fixing portion12of the connecting portion16is a pair of side portions, the face directions of the outside of which are parallel to the longitudinal direction of the first fixing portion12.

At both end portions in the longitudinal direction of the first fixing portion12, bolt insertion holes12aare formed which are used for connecting the first fixing portion12with the object5to be supported. In the second fixing portion14, screw holes14aare formed which are used for fixing the second fixing portion14to the support portion6provided on the vehicle side by fixing screws.

In this connection, instead of providing the bolt insertion holes12ain the first fixing portion12, screw holes for fixing the object5to be supported by fixing screws may be provided. Instead of providing the screw holes14ain the second fixing portion14, bolt insertion holes may be provided.

Manufacturing Method of Supporting Structure

FIG. 3Ais a view showing a casting mold40used in the case of manufacturing the above supporting structure10by means of casting. The casting mold40includes: a first casting mold42and a second casting mold44which are used for forming the first fixing portion12, the second fixing portion14and the connecting portion16; and a third casing mold46which is used for forming a fixing face and a recess hole18of the second fixing portion14.FIG. 3Ais a view showing a state in which the first casting mold42, the second casting mold44and the third casting mold46are matched to each other.

The first casting mold42and the second casting mold44are formed to be a pair of split molds in which a face passing through the center line position in the width direction of the first fixing portion12and also passing through the center line position (position of line C-C inFIG. 2B) of the second fixing portion14is made to be a mold matching face. In the first casting mold42and the second casting mold44, forming faces421,441are formed which are used for forming outer faces of the first fixing portion12, the second fixing portion14and the connecting portion16. In the third casting mold46, a forming face461for forming the fixing face of the second fixing portion14and a protruding body47for forming the recess hole18are formed.

FIGS. 3B and 3Care views showing a state in which the first casting mold42, the second casting mold44and the third casting mold46are matched to each other and a cavity48is formed.FIG. 3Bis a sectional view taken in a direction perpendicular to the mold matching face of the first casting mold42and the second casting mold44.FIG. 3Cis a sectional view taken in a direction parallel to the mold matching face.FIG. 3Cis a view showing the first casting mold42. Concerning the second casting mold44, the cavity is formed in the same manner as that of the first casting mold42.

The cavity48includes forming portions48a,48b,48cby which the first fixing portion12, the second fixing portion14and the connecting portion16are formed. The forming portions48a,48b,48care formed into inner spaces, which are communicated with each other in the casting mold, by the forming faces421,441provided in the first casting mold42and the second casting mold44and by the forming face461provided in the third casting mold46and by the forming face471which is an outer face of the protruding body47. An end face on the protruding side of the protruding body47extends to a portion close to the boundary between the forming portions48aand48c.

A shown inFIG. 3C, a forming portion for forming the side portion16a, the face direction of which is perpendicular to the longitudinal direction of the first fixing portion12of the connecting portion16, includes: a forming face42a(44a), which is formed in the first casting mold42and the second casting mold44, for forming an outside of the connecting portion16; and a forming face47aof the protruding body47opposed to the forming face42a(44a).

As shown inFIG. 3B, a forming portion for forming the side portion16b, the face direction of which is parallel with the longitudinal direction of the first fixing portion12of the connecting portion16, includes: a forming face42b,44bfor forming the outside of the connecting portion16formed in the first casting mold42and the second casting mold44; and a forming face47bof the protruding body47opposed to the forming face42b,44b.

In the present embodiment, the first casting mold42, the second casting mold44and the third casting mold46are matched to each other. Then, molten metal is poured from the gate50into the cavity48by the gravity casting method (GDC). In this way, the supporting structure10is manufactured by means of casting. A casting manufactured by the above casting mold40is composed in such a manner that the first fixing portion12, the second fixing portion14and the connecting portion16are formed being integrated with each other into one body and the recess hole18is formed in a portion located from the second fixing portion14to the connecting portion16. When an insertion hole12ais formed in the first fixing portion12of the this obtained casting by means of machining and a screw hole14ais formed in the second fixing portion14by means of machining, the supporting structure10shown inFIGS. 1 and 2can be obtained.

The thus obtained supporting structure10is composed so that the connecting portion16can be plastically deformed in the loading direction when the object5to be supported, which is supported by the supporting structure10, is given a load not less than a setting value in the loading direction shown inFIG. 1. When the connecting portion16is plastically deformed as described above, it is possible to absorb and relax an intensity of impact energy.

The connecting portion16is formed into a shape which is constricted in the longitudinal direction of the first fixing portion12, that is in the loading direction. Further, the recess hole18is formed in a portion located from the second fixing portion14to the connecting portion16. Furthermore, the wall thickness of the side portion16aperpendicular to the longitudinal direction of the first fixing portion12of the connecting portion16is smaller than the wall thickness of the side portion16bparallel to the longitudinal direction of the first fixing portion12. Due to the above structure, when a load is given in the longitudinal direction of the first fixing portion12, the connecting portion16can be easily plastically deformed.

According to the manufacturing method of a supporting structure of the present embodiment in which the supporting structure10is manufactured by means of casting, a form of the connecting portion16which is deformed when the supporting structure10is given a load, for example, a distance between the side portions16a,16bwhich are opposed to each other can be appropriately set by changing shapes of the forming faces421,441of the first casting mold42and the second casting mold44. Further, the wall thickness of the side portion16a,16bof the connecting portion16can be appropriately set by changing an amount of protrusion and a shape of the protruding body47formed by the forming faces421,441of the first casting mold42and the second casting mold44and by the third casting mold46.

When the recess hole18is formed in the connecting portion18from the second fixing portion14, a weight of the supporting structure10can be reduced. Further, the proof stress of the supporting structure10, at which the plastic deformation is caused, can be adjusted.

When the casting method is employed, an external appearance of the connecting portion can be appropriately formed and further it is possible to easily form a recess hole which is difficult to be formed by means of machining. Furthermore, a shape of the recess hole18can be appropriately formed by changing an amount of protrusion and a shape of the protruding body47formed in the third casting mold46. That is, when the width of the protruding body47is increased or decreased, the wall thickness of the side portion16a,16bof the connecting portion16can be increased or decreased. When the length of protrusion of the protruding body47is extended or reduced, the wall thickness and the inside shape of the connecting portion16can be changed. Accordingly, the proof stress of the connecting portion16, at which the connecting portion16is plastically deformed when a load is given to the connecting portion, can be appropriately adjusted.

In this connection, in the present embodiment, a matching face on which the first casting mold42and the second casting mold44are matched to each other is set to be parallel with the longitudinal direction of the first fixing portion12. However, the supporting structure10of the present embodiment is formed to be symmetrical with respect to the direction perpendicular to the longitudinal direction of the first fixing portion12. Therefore, the casting mold can be formed out of a split mold, the mold matching face of which is in a direction perpendicular to the longitudinal direction of the first fixing portion12. However, in this case, the split mold must be deeply engraved. Therefore, it becomes a little difficult to manufacture the casting mold. As described above, depending upon the form of the supporting structure, a mold matching face of the casting mold can be appropriately selected.

Second Embodiment

FIG. 4Ais a view showing a casting mold used for the second embodiment of the manufacturing method of the supporting structure10. In the same manner as that of the first embodiment, the casting mold40of the present embodiment is formed out of three casting mold including: a first casting mold42and a second casting mold44for forming the first fixing portion12, the second fixing portion14and the connecting portion16; and a third casting mold46for forming a fixing face and a recess hole18of the second fixing portion14.

The present embodiment is characterized in that a groove16cis formed on the outside of the side portion16aperpendicular to the longitudinal direction of the first fixing portion12of the connecting portion16at the time of casting the supporting structure10with the casting mold.

FIG. 4Ais a view showing a state in which a protrusion42c, which is longitudinally arranged in the width direction of the side portion16a, is provided on the forming face42afor forming an outside of the side portion16aof the connecting portion16formed in the first casting mold42. Concerning the second casting mold44, in the same manner as that of the protrusion42cof the first casting mold42, a protrusion44c, which is longitudinally arranged in the width direction of the side portion16a, is provided.

FIG. 4Bis a plan view (Concerning the connecting portion16, a cross section is shown.) of the supporting structure10obtained by means of casting in which the first casting mold42and the second casting mold44, having the protrusions42c,44c, and the third casting mold46having the protruding body47are used. When casting is conducted with the first casting mold42and the second casting mold44having the protrusions42c,44c, it is possible to obtain a supporting structure in which the groove16cis formed on the side portion16a,16aperpendicular to the longitudinal direction of the first fixing portion12of the connecting portion16.

In the supporting structure10, on the outside of the connecting portion16of which the groove16cis formed, the wall thickness of the side portion16aof the connecting portion16is partially reduced in a portion in which the groove16cis formed. Therefore, when an object to be supported is given a load, the load concentrates upon a portion of the connecting portion16in which the groove16cis formed. Accordingly, the proof stress, at which plastic deformation of the supporting portion16is made, can be reduced as compared with a case in which the groove16cis not formed.

When machining is conducted on a casting, it is possible to form the groove16cin the connecting portion16. However, according to the method in which the groove16cis formed simultaneously when the supporting structure10is formed by casting with the casting mold40, the supporting structure10, in the connecting portion16of which the groove16cis formed, can be simply manufactured.

In the present embodiment, an example is shown in which one groove16cis formed in the connecting portion16. However, it is possible to form a plurality of grooves16cin the connecting portion16. Further, it is possible to appropriately adjust the width and depth of the groove16c. A form of the groove16ccan be appropriately set by changing the form of the protrusion42c,44cmanufactured in the casting mold. As long as it is a method of manufacturing a supporting structure by means of casting, it is easy to manufacture a supporting structure10provided with a connecting portion16, the form of which is appropriately determined. It is possible to manufacture the supporting structure10, the proof stress, at which the connecting portion16is plastically deformed, of which is appropriately adjusted.

Third Embodiment

FIG. 5Ais a view showing a casting mold used for the third embodiment of the manufacturing method of the supporting structure10. In the same manner as that of the first and the second embodiment, in the present embodiment, the supporting structure10is manufactured by means of casting with the first casting mold42, the second casting mold44and the third casting mold46described before.

The present embodiment is characterized in that a recess portion16dis formed on the outside16bparallel with the longitudinal direction of the first fixing portion12of the connecting portion16at the time of casting the supporting structure10with the casting mold.

FIG. 5Ais a view showing a state in which a protruding portion42d,44dfor forming the recess portion16dis formed on the forming face42b,44bwhich forms an outside of the side portion16bof the connecting portion16formed in the first casting mold42and the second casting mold44.

FIG. 5Bis a plan view (Concerning the connecting portion16, a section is shown.) of the supporting structure10made by casting with the first casting mold42and the second casting mold44having the protruding portion42d,44d. Since casting is conducted with the first casting mold42and the second casting mold44having the protruding portion42d,44d, it is possible to obtain a supporting structure10, in the side portion16bof the connecting portion16of which the recess portion16dis formed.

In the supporting structure10in which the recess portion16dis formed in the side portion16bwhich is parallel with the longitudinal direction of the first fixing portion12, the wall thickness of a portion in the connecting portion16in which the recess portion16dis formed is so small that a cross-sectional area of the connecting portion16is reduced. Therefore, the proof stress, at which the connecting portion16is plastically deformed when the connecting portion16is given a load, can be decreased as compared with a case in which the recess portion16dis not formed.

Concerning the recess portion16dformed in the side portion16b, it is possible to appropriately set the depth and width. Further, it is possible to form a plurality of recess portions16d. When a form and arrangement of the recess portion16dformed in the connecting portion16are appropriately set as described above, it is possible to adjust the proof stress at which the connecting portion16is plastically deformed.

In the case where the recess portion16dis formed in the side portion16bof the connecting portion16, in relation to the recess hole18formed inside of the connecting portion16by the protruding body47provided in the third casting mold46, when the wall thickness of the connecting portion16is adjusted or the cross sectional shape of the connecting portion16is adjusted, it is possible to adjust the proof stress at which the connecting portion16is plastically deformed.

As described above, the protruding body47formed in the third casting mold46provides the weakest portion, which is plastically deformed when a load is given to the supporting structure10, in the connecting portion16by reducing the wall thickness of the connecting portion16. According to a combination of the form of the protruding body47provided in the third casting mold46and the form of the groove16c, which is formed on the outer face of the connecting portion16, or the recess portion16d, the proof stress, at which the connecting portion16is plastically deformed with respect to a load acting on the supporting structure10, can be variously set.

In the case of employing the manufacturing method in which the supporting structure is manufacture by the casting method, by a combination of the casting mold, it is possible to manufacture various supporting structure10in which a form of the connecting portion16, a form of the first fixing portion12and a form of the second fixing portion14are varied. That is, according to the manufacturing method of the supporting structure for vehicle of the present invention, when the supporting structure is manufactured by the casting method, it is possible to inexpensively manufacture various products having a function of absorbing and relaxing impact energy, which is necessary for the supporting structure10, according to the form of the object to be supported by the supporting structure10and the attaching position of the object to be supported.

In this connection, the above explanations are made into an example in which the supporting structure10is given a load as shown inFIG. 1A. However, even in the case where the loading direction is different from that shown inFIG. 1A, an external appearance of the connecting portion16and a cross-sectional shape can be appropriately designed. Therefore, it is possible to manufacture a supporting structure having a function of absorbing a predetermined impact energy.

Concerning the casting method, the common gravity casting method is used in the embodiment described above. However, the casting method is not limited to the gravity casting method. It is possible to use a well known casting method such as a die-casting method (DC), a low pressure casting method (LPD) or a reduction casting method.