Structure for vehicle suspension and method for manufacturing same

Abstract

The invention provides a structure for a vehicle suspension, which can improve the rigidity of a connecting part without using other components. A vehicle suspension structure (vehicle suspension arm) (11) has a first plate material (40) and a second plate material (50), and has a first connection section (22) that connects a constituent member (30) (collar (31)). The first plate material has a flange section (48) bent with respect to the first flat plate section (42). The flange portion of the first plate material overlaps and is joined to the second main body portion 51 of the second plate material. A portion of the first plate material facing the first flat plate portion is open so that a first attachment surface 43 can be formed by press working in a single body state in which the first flat plate portion is bent. A portion of the second plate material facing the second flat plate portion (52) is also open. The connection portion is configured by disposing a first mounting surface and a second mounting surface 53 so that a first flat plate portion of the first plate material and a second flat plate portion of the second plate material face each other with a gap therebetween, and the first mounting surface and the second mounting surface 53 are disposed with a gap therebetween.

Description

Technical Field

[0001] The present invention relates to a vehicle suspension structure and a manufacturing method thereof. Background Art

[0002] The vehicle suspension device has a plurality of components such as a vehicle suspension structure and a shock absorber. Examples of the vehicle suspension structure include a vehicle suspension arm and a vehicle suspension assembly. The vehicle suspension structure has a connection portion for connecting the vehicle suspension components.

[0003] As a vehicle suspension arm mounted on the front of a vehicle, for example, a lower arm having a shape roughly similar to the letter "λ" when viewed from above is known (see Patent Document 1). The lower arm is a component of a double wishbone front suspension, and has a connection portion to which a collar is connected by welding at each end of the arm divided into two branches. The collar is a component of a vehicle suspension, and connects the lower arm to the vehicle body in a swingable manner. The connection portion is formed by a plurality of wall portions. The connection portion has a collar matching surface corresponding to the shape of the outer peripheral surface of the collar.

[0004] Prior art literature

[0005] Patent Literature

[0006] Patent Document 1: U.S. Patent No. 10543726 Summary of the invention

[0007] Problem that the invention aims to solve

[0008] The connection part must have sufficient rigidity to resist the force input from the tire through the ball joint. The location where the connection part is formed is also restricted by the vehicle layout. Therefore, it is difficult to increase the cross-sectional shape of the connection part and improve the rigidity. Although it is also possible to increase the plate thickness of the wall part of the connection part to improve the rigidity, it will increase the weight of the component and increase the manufacturing cost.

[0009] The lower arm disclosed in Patent Document 1 has a support column disposed near the connection portion in order to increase the rigidity of the connection portion.

[0010] However, it is necessary to manufacture the support column as a component separate from the main body of the lower arm or to join the support column to the main body by welding, which complicates the manufacturing process and increases the manufacturing cost.

[0011] In view of the above, an object of the present invention is to provide a vehicle suspension structure and a method for manufacturing the same, wherein the vehicle suspension structure can improve the rigidity of a connection portion without using other components.

[0012] Solutions to the problem

[0013] One embodiment of the present invention is a vehicle suspension structure, which has at least a first plate and a second plate as a stamped product, and has a main body and a connection portion for connecting a component for a vehicle suspension. The first plate includes a first main body, a first flat plate, a first mounting surface, and a flange, wherein the first main body constitutes the main body, the first flat plate is continuous on the main surface of the first main body and extends in a curved manner relative to the main surface, the first mounting surface is formed on the first flat plate and abuts against the outer surface of the component, and the flange is continuous on the first flat plate and bends relative to the first flat plate, and extends further outward than the main surface of the first main body. The second plate includes a second main body, a second flat plate, and a second mounting surface, wherein the second main body constitutes the main body together with the first main body of the first plate, the second flat plate is continuous on the main surface of the second main body and extends in a curved manner relative to the main surface, and the second mounting surface is formed on the second flat plate and abuts against the outer surface of the component. The portion of the first plate facing the first flat plate is open, so that the first mounting surface can be formed by stamping in the state of the bent single body of the first flat plate. The portion of the second plate facing the second flat plate portion is open, so that the second mounting surface can be formed by stamping in a state where the second flat plate portion is bent as a single body. The main body portion is formed by making the first main body portion of the first plate and the second main body portion of the second plate face each other. The connecting portion is formed by making the first flat plate portion of the first plate and the second flat plate portion of the second plate face each other with a gap therebetween, and arranging the first mounting surface and the second mounting surface with a gap therebetween. The flange portion of the first plate is overlapped and joined to the second main body portion of the second plate.

[0014] Another embodiment of the present invention is a method for manufacturing a vehicle suspension structure, which has at least a first plate and a second plate as stamped products, and has a main body and a connection portion for connecting a component for a vehicle suspension. A first main body, a first flat plate and a flange are formed on the first plate, the first main body constituting the main body, the first flat plate being continuous on the main surface of the first main body and extending in a curved manner relative to the main surface, and the flange being continuous on the first flat plate and extending in a curved manner relative to the first flat plate, and extending outward from the main surface of the first main body. The first plate, which is bent by the first flat plate, is pressed against a die, and a first mounting surface abutting against the outer surface of the component is formed on the first flat plate. A second main body and a second flat plate are formed on the second plate, the second main body constituting the main body together with the first main body of the first plate, the second flat plate being continuous on the main surface of the second main body and extending in a curved manner relative to the main surface. The second plate, which is bent by the second flat plate, is pressed against the die, and a second mounting surface abutting against the outer surface of the component is formed on the second flat plate. The first main body portion of the first plate and the second main body portion of the second plate are placed in a state of facing each other, and the first flat plate portion of the first plate and the second flat plate portion of the second plate are placed in a state of facing each other with a gap therebetween, and the first mounting surface and the second mounting surface are arranged with a gap therebetween, and then the flange portion of the first plate is overlapped on the second main body portion of the second plate, and the first plate and the second plate are integrated by welding to form the main body portion and the connecting portion.

[0015] Effects of the Invention

[0016] According to the present invention, it is possible to provide a vehicle suspension structure capable of improving the rigidity of a connection portion without using other components, and a method for manufacturing the same. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 This is a perspective view showing a vehicle suspension arm as a vehicle suspension structure according to an embodiment in a state where components for a vehicle suspension are mounted.

[0018] Figure 2 This is a perspective view showing a vehicle suspension arm in a state where a first plate and a second plate are separated.

[0019] Figure 3 A top view showing a vehicle suspension arm.

[0020] Figure 4 For Figure 3A forward view of the connecting portion of the vehicle suspension arm as viewed from the direction indicated by arrow 4.

[0021] Figure 5 It is a perspective view showing the vicinity of a connection portion of a vehicle suspension arm.

[0022] Figure 6 For Figure 3 The arrow 6 is a view showing other connecting parts of the vehicle suspension arm when viewed from the direction indicated by the arrow.

[0023] Figure 7 It is a perspective view showing the vicinity of another connection portion of the vehicle suspension arm.

[0024] Figure 8 For along Figure 3 Cross-sectional view of line 8-8.

[0025] Fig. 9 For along Figure 3 Cross-sectional view of line 9-9.

[0026] Fig.10 The figure schematically shows the process of forming the flange portion on the first plate material.

[0027] Fig.11 The figure is a cross-sectional view schematically showing a state where a first sheet material is set on a die.

[0028] Explanation of symbols

[0029] 11 Suspension arm (structure for vehicle suspension, arm for vehicle suspension), 20 Arm body (body), 21 Wheel support part, 22 First connection part (connection part), 24 Second connection part (other connection part), 25 Bend part, 30 Component for vehicle suspension, 31 Collar, 40 First plate, 41 First body, 41a Main surface of first body, 42 First flat plate, 43 First mounting surface, 44 First end surface, 45 First extension, 48 Flange, 49 Blank, 49a Bend part, 50 Second plate, 51 Second body, 51a Main surface of second body, 52 Second flat plate, 52a End of second flat plate, 53 Second mounting surface, 54 Second end surface, 55 Second extension, 60 Die concave mold, 63 Convex mold DETAILED DESCRIPTION

[0030] Hereinafter, the mode for implementing the present invention will be described in detail with reference to the accompanying drawings. The embodiments shown here are listed for the purpose of specifying the technical concept of the present invention and are not intended to limit the present invention. Therefore, within the scope of the present invention, other practicable modes, embodiments and application technologies that can be thought of by those skilled in the art are all included in the scope and purpose of the present invention, and are included in the invention described in the claims and the scope equivalent thereto.

[0031] Furthermore, for the sake of convenience of illustration and easy understanding, the drawings accompanying this specification may schematically present appropriate scales, aspect ratios, shapes, etc. that are changed from the actual objects, but these are merely examples and are not intended to limit the interpretation of the present invention.

[0032] In addition, in this specification, ordinal numbers such as "first" and "second" are sometimes added. However, unless otherwise specified, these ordinal numbers are given for the convenience of identifying components in the description and are not used to determine quantity or order.

[0033] The vehicle suspension device has a plurality of components such as a vehicle suspension structure and a shock absorber. As the vehicle suspension structure, for example, there are a vehicle suspension arm and a vehicle suspension assembly. The vehicle suspension structure of the present invention has at least a first plate and a second plate as stamped products, and has a main body and a connecting portion for connecting components for vehicle suspension. As the vehicle suspension structure, for example, there are a vehicle suspension arm and a vehicle suspension assembly. The following describes an embodiment in which the vehicle suspension structure of the present invention is applied to a vehicle suspension arm.

[0034] Implementation

[0035] Reference Figures 1 to 11 , a vehicle suspension arm 11 according to an embodiment will be described. Figures 1 to 9 It is a diagram for explaining the configuration of each part of the vehicle suspension arm 11 according to the embodiment. Fig.10 , Fig.11 It is a diagram for explaining processing of the first plate material 40 of the vehicle suspension arm 11 .

[0036] like Figure 1 to Figure 3 As shown, the vehicle suspension arm 11 (hereinafter, also simply referred to as "suspension arm 11") of the embodiment is used as a lower arm, which is a component of a double wishbone front suspension provided in a vehicle such as an automobile. The suspension arm 11 is mounted at the front lower portion of the vehicle.

[0037] like Figure 3 As shown in FIG. 1 , the suspension arm 11 has an arm main body 20 (corresponding to the main body) which is substantially in the shape of a letter "λ" in a plan view. Figure 3 The wheel support portion 21 is disposed at the end shown in the upper middle side. The wheel support portion 21 is swingably connected to a wheel support member (not shown) via a ball joint. The arm body 20 extends from the wheel support portion 21 to the Figure 3 In the way of splitting into two strands. Figure 3 In the embodiment, a first connecting portion 22 (corresponding to a connecting portion) for connecting a component 30 for a vehicle suspension is arranged at the left end. Figure 3In the embodiment, a second connection portion 24 (corresponding to another connection portion) is arranged at the right end portion to connect another component 30 for vehicle suspension. The first connection portion 22 and the second connection portion 24 function as a vehicle body connection portion.

[0038] In the embodiment, the same component is used as the component 30 and the other component 30. In addition, in the embodiment, the first connection portion 22 and the second connection portion 24 are configured in the same manner. Therefore, the same reference numerals are given to the components configuring the first connection portion 22 and the components configuring the second connection portion 24.

[0039] like Figure 1 , Figure 2 As shown, in the embodiment, the component 30 is, for example, a metal cylindrical component, generally referred to as a collar 31. The collar 31 has a hollow cylindrical shape, and a resin sleeve (not shown) is pressed into the interior thereof. A connecting pin (not shown) is inserted through the center of the sleeve. The axis of the collar 31, the sleeve, and the connecting pin is, for example, along the front-rear direction of the vehicle body. The collar 31 connects the arm body 20 to the vehicle body in a swingable manner.

[0040] like Figure 1 , Figure 2 , Figure 4 , Figure 5 , Figure 6 , Figure 7 , Figure 8 and Fig. 9 As shown, the suspension arm 11 has at least a first plate 40 and a second plate 50 as stamped products. The suspension arm 11 shown in the figure is formed by two plates (a first plate 40 and a second plate 50). The first plate 40 is also called an upper plate, and the second plate 50 is also called a lower plate. The first plate 40 and the second plate 5 have a substantially lambda shape when viewed from above. The suspension arm 11 has an arm body 20 and a first connecting portion 22 and a second connecting portion 24. The arm body 20 has a rectangular cross-section (see Fig. 9 ) position, the first connecting portion 22 and the second connecting portion 24 are connected to a component 30 for a vehicle suspension.

[0041] like Figure 1 , Figure 2 , Figure 4 , Figure 5 , Figure 6 and Figure 7As shown, the first plate 40 includes a first main body 41, a first flat plate 42, and a first mounting surface 43. The first main body 41 constitutes the arm main body 20. The first flat plate 42 is continuous on the main surface 41a of the first main body 41 and extends in a curved manner relative to the main surface 41a. The first mounting surface 43 is formed on the first flat plate 42 and abuts against the outer surface of the collar 31. The first plate 40 also includes a flange 48 that is continuous on the first flat plate 42 and curved relative to the first flat plate 42. The first flat plate 42 is curved from the main surface 41a of the first main body 41 to the side facing the second plate 50. The flange 48 is curved to the side extending further outward than the main surface 41a of the first main body 41.

[0042] Here, the “main surface 41a of the first main body portion 41” refers to a portion constituting the main body of the first main body portion 41. Figure 1 , Figure 2 The upper part of the arm main body 20 shown in the upper middle side. The term "face" in "main surface 41a" does not distinguish the front side ( Figure 1 and Figure 2 The main surface 41a has a gentle concave-convex shape to ensure the rigidity of the first main body 41. The curved first flat plate portion 42 constitutes a part of the side portion of the arm main body 20. Figure 3 As shown, “outward from the main surface 41 a of the first body portion 41 ” means a direction extending outward from the main surface 41 a when viewed from above in a direction intersecting the main surface 41 a of the first body portion 41 .

[0043] The second plate 50 has a second main body 51, a second flat plate 52, and a second mounting surface 53. The second main body 51 and the first main body 41 of the first plate 40 together constitute the arm main body 20. The second flat plate 52 is continuous on the main surface 51a of the second main body 51 and extends in a curved manner relative to the main surface 51a. The second mounting surface 53 is formed on the second flat plate 52 and abuts against the outer surface of the collar 31. The second flat plate 52 is curved from the main surface 51a of the second main body 51 to the side facing the first plate 40.

[0044] Here, the “main surface 51a of the second main body portion 51” refers to a portion constituting the main body of the second main body portion 51. Figure 2 The lower part of the arm main body 20 shown in the middle lower side. The term "face" in "main surface 51a" does not distinguish the front side ( Figure 2 The main surface 51a may have a gentle concavo-convex shape. The curved second flat plate portion 52 constitutes a part of the side portion of the arm body portion 20.

[0045] like Figure 2 , Figure 4 , Figure 5 , Figure 6 , Figure 7 and the following Fig.11 As shown, the portion of the first plate 40 facing the first flat plate portion 42 is open, so that the first mounting surface 43 can be formed by stamping in the state of the first flat plate portion 42 being bent alone. Similarly, the portion of the second plate 50 facing the second flat plate portion 52 is open, so that the second mounting surface 53 can be formed by stamping in the state of the second flat plate portion 52 being bent alone.

[0046] The arm body portion 20 is formed by having the first body portion 41 of the first plate member 40 and the second body portion 51 of the second plate member 50 facing each other.

[0047] The first connection portion 22 and the second connection portion 24 are formed by making the first flat plate portion 42 of the first plate 40 and the second flat plate portion 52 of the second plate 50 face each other with a gap therebetween, and arranging the first mounting surface 43 and the second mounting surface 53 with a gap therebetween.

[0048] like Figure 4 , Figure 5 , Figure 6 , Figure 7 , Figure 8 and Fig. 9 As shown, the flange portion 48 of the first plate 40 is overlapped on the second body portion 51 of the second plate 50 for bonding. The flange portion 48 is formed on the first flat plate portion 42 forming the first mounting surface 43. Therefore, the rigidity of the first flat plate portion 42 can be improved, and the collar 31 can be firmly mounted on the first mounting surface 43.

[0049] The first flat plate portion 42 is disposed at one end (eg, Figure 8 The first main body 41 is disposed at the upper end thereof, and at the other end thereof (for example, Figure 8 The flange portion 48 is disposed at the lower end of the first mounting surface 43. Therefore, even if the flange portion 48 is provided, the welding margin between the first mounting surface 43 and the collar 31 will not be interrupted, and a relatively long welding margin can be ensured. Therefore, the collar 31 can be firmly mounted on the first mounting surface 43.

[0050] like Figure 8 As shown, along the direction in which the flange portion 48 overlaps with the second main body portion 51 of the second plate 50, the first main body portion 41 of the first plate 40 abuts against the end portion 52a of the second flat plate portion 52 of the second plate 50 to engage with the second flat plate portion 52. By abutting the first main body portion 41 against the end portion 52a of the second flat plate portion 52, the positions of the first plate 40 and the second plate 50 in the vertical direction in the figure during assembly are determined. Therefore, the first plate 40 and the second plate 50 can be easily positioned, and the assembly performance is improved.

[0051] Furthermore, the first plate 40 and the second plate 50 are assembled simply by placing the first plate 40 on the second plate 50 from above. Therefore, the gap between the first plate 40 and the second plate 50 can be easily managed, and the welding performance is improved. The first plate 40 and the second plate 50 can be welded from the lower side in the figure to the flange portion 48 and the second main body portion 51, and the first main body portion 41 and the second flat plate portion 52 can be welded from the lower side in the figure. There is no need to reverse the posture of the first plate 40 and the second plate 50, or to significantly change the position or posture of the welding machine. Therefore, the welding performance is improved.

[0052] In addition, if Figure 2 , Figure 8 and Fig. 9 As shown, in order to improve the rigidity of the first connection part 22 and the second connection part 24, the portion where the first main body part 41 abuts against the end 52a of the second flat plate part 52 is limited to a portion close to the second mounting surface 53. However, a configuration in which the entire end 52a of the second flat plate part 52 abuts against the first main body part 41 may also be formed.

[0053] The first plate 40 and the second plate 50 are integrated by fillet welding 76 and 77 (see Figure 8 , Fig. 9 ) The reference numerals 76 and 77 of the fillet welds 76 and 77 represent welding beads.

[0054] There is no particular limitation on the angle formed by the first flat plate portion 42 and the main surface 41a of the first main body portion 41. Figure 4 , Figure 5 , Figure 6 , Figure 7 and Figure 8 As shown, the first flat plate portion 42 may be bent into an L shape relative to the main surface 41a of the first main body portion 41. Figure 8 As shown, “bent into an L shape” means that the cross-sectional shape of the first flat plate portion 42 and the main surface 41 a is bent into a substantially L shape when viewed in a cross section perpendicular to a bending line between the first flat plate portion 42 and the first main body portion 41 .

[0055] There is no particular limitation on the angle formed by the flange portion 48 and the first flat plate portion 42. As an example, Figure 4 , Figure 5 , Figure 6 , Figure 7 and Figure 8 As shown, the flange portion 48 can be bent into an L shape relative to the first flat plate portion 42. Figure 8As shown, “bent into an L-shape” means that the cross-sectional shape of the flange portion 48 and the first flat plate portion 42 is bent into a substantially L-shape when viewed in a cross section perpendicular to a bending line between the flange portion 48 and the first flat plate portion 42 .

[0056] There is no particular limitation on the angle formed by the second flat plate portion 52 and the main surface 51a of the second main body portion 51. Figure 4 , Figure 5 , Figure 6 , Figure 7 and Figure 8 As shown, the second flat plate portion 52 can be bent into an L shape relative to the main surface 51a of the second main body portion 51. "Bent into an L shape" means that when observing the cross section orthogonal to the bending line between the second flat plate portion 52 and the second main body portion 51, the cross-sectional shape of the second flat plate portion 52 and the main surface 51a is bent into a substantially L shape.

[0057] like Figure 3 As shown in FIG. 1 , the arm body 20 has a curved portion 25, and when viewed from above from a direction intersecting the main surface 41a of the first body 41, the curved portion 25 has a contour that is curved from the first connection portion 22 toward the inside of the arm body 20. The flange portion 48 is formed on the first flat plate portion 42 located at the curved portion 25. Therefore, the first plate 40 can improve the rigidity (bending rigidity) of the curved portion 25 extending from the first connection portion 22. In particular, the flange portion 48 can strengthen the rigidity (bending rigidity) of the curved portion 25 near the first connection portion 22.

[0058] Here, if Figure 3 As shown, “from the first connection portion 22 toward the inner side of the arm body 20” means that the contour of the arm body 20 is concave from the first connection portion 22 toward the direction ( Figure 3 Upper middle side).

[0059] In addition to the first connection portion 22 connected to the component 30 (shaft collar 31), the suspension arm 11 of the embodiment also has a second connection portion 24 connected to another component 30 (shaft collar 31). Figure 3As shown, the arm body portion 20 has the above-mentioned bent portion 25 between the first connection portion 22 and the second connection portion 24 when viewed from above from a direction intersecting the main surface 41a of the first body portion 41, and the bent portion 25 has a contour bent toward the inside of the arm body portion 20. The flange portion 48 is formed on the first flat plate portion 42 located at the bent portion 25. In the embodiment, the bent portion 25 constitutes a portion that is divided into two branches toward the first connection portion 22 and the second connection portion 24. Therefore, the first plate 40 can improve the rigidity (bending rigidity) of the bent portion 25 extending between the first connection portion 22 and the second connection portion 24. In particular, the flange portion 48 can strengthen the rigidity (bending rigidity) near the first connection portion 22 and the rigidity (bending rigidity) near the second connection portion 24 in the bent portion 25.

[0060] like Figure 4 , Figure 5 , Figure 6 and Figure 7 As shown, the first mounting surface 43 is formed by the first end surface 44 formed at the end of the first flat plate portion 42, and the second mounting surface 53 is formed by the second end surface 54 formed at the end of the second flat plate portion 52. The collar 31 is mounted on the first connecting portion 22 and the second connecting portion 24 by fillet welding with the first end surface 44 and the second end surface 54, respectively. With this configuration, the first mounting surface 43 and the second mounting surface 53 form surfaces facing outward, and the collar 31 can be easily mounted by fillet welding.

[0061] like Figure 2 , Figure 5 and Figure 7 As shown, the first plate 40 further includes a first extension portion 45, which is continuous on the main surface 41a of the first main body portion 41 and extends further toward the outside of the first main body portion 41 than the first flat plate portion 42. The second plate 50 further includes a second extension portion 55, which is continuous on the main surface 51a of the second main body portion 51 and extends further toward the outside of the second main body portion 51 than the second flat plate portion 52. The first extension portion 45 and the second extension portion 55 can be extended from the direction ( Figure 5 and Figure 7 The direction of the cross ( Figure 5 and Figure 7 The collar 31 is clamped in the vertical direction of the first extension portion 45. The collar 31 is attached to the first connection portion 22 and the second connection portion 24 by fillet welding to the end surface of the first extension portion 45 and the end surface of the second extension portion 55. As a result, the component 30 (collar 31) can be more firmly attached to the first connection portion 22 and the second connection portion 24.

[0062] like Fig.11As shown, the first mounting surface 43 is formed by stamping the first plate 40 in a single body by bending the first flat plate portion 42. The stamping device, for example, has a cam driver and a cam slider. By cutting the first flat plate portion 42 through cam-type stamping, the first mounting surface 43 corresponding to the shape of the outer peripheral surface of the collar 31 can be formed.

[0063] Similarly, the second mounting surface 53 is formed by pressing the second plate 50 in a single state by bending the second flat plate portion 52. The second mounting surface 53 corresponding to the shape of the outer peripheral surface of the collar 31 can be formed by cutting the second flat plate portion 52 by cam-type pressing.

[0064] like Fig.11 As shown, when forming the first mounting surface 43, the first plate 40 with the first flat plate portion 42 and the flange portion 48 bent is abutted against the die 60 (equivalent to the die) for stamping. The width W of the die 60 is formed to ensure a strength that can withstand the load during stamping. The portion of the first plate 40 where the first flat plate portion 42 and the first extension portion 45 are formed has a substantially L-shaped cross section, and the portion facing the first flat plate portion 42 is open. The first plate 40 is positioned by abutting the first extension portion 45 against the top of the die 60 and abutting the first flat plate portion 42 against the side of the die 60. In this state, a punch 63 is used for stamping, and a portion of the first flat plate portion 42 is cut off to form the first mounting surface 43. The die 60 has a space portion 60a into which the front end portion of the punch 63 can enter. The space portion 60a is connected to a chute (not shown) for discharging the waste material cut off by the punch 63.

[0065] Similarly, when forming the second mounting surface 53, the second plate 50 with the bent second flat plate portion 52 is pressed against the die 60. The portion of the second plate 50 where the second flat plate portion 52 and the second extension portion 55 are formed has a substantially L-shaped cross section, and the portion facing the second flat plate portion 52 is open. The second plate 50 is positioned by causing the second extension portion 55 to abut against the top of the die 60 and causing the second flat plate portion 52 to abut against the side of the die 60. In this state, a press is performed using the punch 63 to cut off a portion of the second flat plate portion 52 to form the second mounting surface 53.

[0066] Due to constraints such as the layout of the vehicle body, the axial length of the collar 31 may be set relatively short. In this case, the width of the first extension portion 45 may be smaller than the width of the die 60. Even in this case, since the cross section of the portion abutting against the die 60 has a substantially L-shaped shape, the first flat plate portion 42 and the first extension portion 45 can be abutted against the die 60, and the first mounting surface 43 can be formed without hindrance. Similarly, even in the case where the width of the second extension portion 55 is smaller than the width of the die 60, since the cross section of the portion abutting against the die 60 has a substantially L-shaped shape, the second flat plate portion 52 and the second extension portion 55 can be abutted against the die 60, and the second mounting surface 53 can be formed without hindrance. Therefore, there is no need to use a laser cutting device or the like instead of a stamping process to form the first mounting surface 43 and the second mounting surface 53, and an increase in manufacturing costs can be suppressed.

[0067] As described above, the portion of the first plate 40 where the first flat plate portion 42 and the first extension portion 45 are formed has a substantially L-shaped cross section, so that the first mounting surface 43 can be formed without hindrance. Figure 4 , Figure 5 , Figure 6 and Figure 7 As shown, the flange portion 48 can be formed as close as possible to the base of the first mounting surface 43. Therefore, the rigidity near the base of the first mounting surface 43 can be increased without increasing the plate thickness or reinforcing with other components. As a result, the collar 31 can be firmly mounted on the first mounting surface 43.

[0068] Next, a manufacturing procedure of the suspension arm 11 will be described.

[0069] The suspension arm 11 includes a first plate 40 and a second plate 50 , and includes an arm body 20 and a first connecting portion 22 and a second connecting portion 24 to which the collar 31 is mounted.

[0070] First, a first main body portion 41, a first flat plate portion 42 and a flange portion 48 are formed on the first plate material 40, the first main body portion 41 constitutes the arm main body portion 20, the first flat plate portion 42 is continuous on the main surface 41a of the first main body portion 41 and extends bent relative to the main surface 41a, and the flange portion 48 is continuous on the first flat plate portion 42 and bends relative to the first flat plate portion 42, and extends further toward the outside than the main surface 41a of the first main body portion 41.

[0071] As in Fig.10As shown schematically, first, the blank 49 is punched by the dies 61a and 61b, and the blank 49 is deep-drawn. Thus, the first main body 41, the first flat plate 42, and the curved portion 49a that is continuous on the first flat plate 42 and curved relative to the first flat plate 42 are formed from the blank 49. The curved portion 49a constitutes the bottom plate portion. Subsequently, the dies 62a and 62b are punched to trim the unnecessary portion of the curved portion 49a. Thus, the first main body 41, the first flat plate 42, and the flange 48 are formed on the first plate 40.

[0072] The first plate material 40 having the bent first flat plate portion 42 is brought into contact with the die 60 for press working, thereby forming the first mounting surface 43 in contact with the outer surface of the collar 31 on the first flat plate portion 42 .

[0073] Similarly, the second plate 50 includes a second main body 51 and a second flat plate 52 . The second main body 51 and the first main body 41 constitute the arm main body 20 . The second flat plate 52 is continuous with the main surface 51 a of the second main body 51 and extends in a curved manner relative to the main surface 51 a .

[0074] The second plate material 50 having the bent second flat plate portion 52 is brought into contact with a die and subjected to press working, so that the second mounting surface 53 that comes into contact with the outer surface of the collar 31 is formed on the second flat plate portion 52 .

[0075] Furthermore, the first main body portion 41 of the first plate 40 and the second main body portion 51 of the second plate 50 are formed to face each other. Furthermore, the first flat plate portion 42 of the first plate 40 and the second flat plate portion 52 of the second plate 50 are formed to face each other with a gap therebetween, and the first mounting surface 43 and the second mounting surface 53 are formed to be arranged with a gap therebetween. Furthermore, the flange portion 48 of the first plate 40 and the second main body portion 51 of the second plate 50 are formed to overlap. In this state, the first plate 40 and the second plate 50 are integrated by welding, thereby forming the arm main body portion 20, the first connecting portion 22, and the second connecting portion 24.

[0076] During assembly, the first body 41 of the first plate 40 abuts against the end 52a of the second flat plate 52 of the second plate 50 in a direction that the flange 48 overlaps the second body 51 of the second plate 50. In this state, the first body 41 is welded to the second flat plate 52.

[0077] As described above, the suspension arm 11 of the embodiment has the first plate 40 and the second plate 50 as stamped products, and has the arm body 20 and the first connecting portion 22 for connecting the component 30 (shaft collar 31) for the vehicle suspension. The first plate 40 has the first body 41, the first flat plate 42, the first mounting surface 43 and the flange 48, the first body 41 constituting the arm body 20, the first flat plate 42 is continuous on the main surface 41a of the first body 41 and extends in a curved manner relative to the main surface 41a, the first mounting surface 43 is formed on the first flat plate 42 and abuts against the outer surface of the component 30 (shaft collar 31), and the flange 48 is continuous on the first flat plate 42 and is curved relative to the first flat plate 42, and extends further toward the outside than the main surface 41a of the first body 41. The second plate 50 has a second main body 51, a second flat plate 52, and a second mounting surface 53. The second main body 51 constitutes the arm main body 20 together with the first main body 41 of the first plate 40. The second flat plate 52 is continuous on the main surface 51a of the second main body 51 and extends in a curved manner relative to the main surface 51a. The second mounting surface 53 is formed on the second flat plate 52 and abuts against the outer surface of the component 30 (shaft collar 31). The portion of the first plate 40 facing the first flat plate 42 is open, so that the first mounting surface 43 can be formed by stamping in the state of the first flat plate 42 being bent alone. The portion of the second plate 50 facing the second flat plate 52 is open, so that the second mounting surface 53 can be formed by stamping in the state of the second flat plate 52 being bent alone. The arm main body 20 is constituted by making the first main body 41 of the first plate 40 and the second main body 51 of the second plate 50 face each other. The first connection portion 22 is formed by placing the first flat plate portion 42 of the first plate 40 and the second flat plate portion 52 of the second plate 50 facing each other with a gap therebetween and arranging the first mounting surface 43 and the second mounting surface 53 with a gap therebetween. The flange portion 48 of the first plate 40 is overlapped and joined to the second body portion 51 of the second plate 50.

[0078] According to the suspension arm 11 of such a configuration, the flange portion 48 is formed on the first flat plate portion 42 where the first mounting surface 43 is formed. Therefore, the rigidity of the first flat plate portion 42 can be improved, and the component 30 (shaft collar 31) can be firmly mounted on the first mounting surface 43. The portion where the flange portion 48 is formed is not a portion restricted by the vehicle layout. Therefore, the size and position of the flange portion 48 can be determined without being restricted by the vehicle layout. Therefore, the design for improving the rigidity of the first connection portion 22 becomes easy. Furthermore, the rigidity of the first connection portion 22 can be improved without manufacturing or welding other components (for example, the support of Patent Document 1). Moreover, even if the axial length of the component 30 (shaft collar 31) is set to be relatively short due to restrictions such as the vehicle body layout, since the cross section of the portion including the first flat plate portion 42 and the second flat plate portion 52 has a substantially L-shaped shape, the first mounting surface 43 and the second mounting surface 53 can be formed without hindrance by stamping the first plate 40 and the second plate 50 in a single state. Therefore, it is not necessary to use a laser cutting device or the like instead of a stamping process to form the first mounting surface 43 and the second mounting surface 53, and it is possible to suppress an increase in manufacturing costs. Thus, it is possible to improve the rigidity of the first connecting portion 22 without using other components, and further, even when the axial length of the component 30 (shaft collar 31) is short, it is possible to provide a suspension arm 11 that can form the first connecting portion 22 for mounting the component 30 (shaft collar 31) by a cost-effective stamping process.

[0079] Along the direction in which the flange portion 48 overlaps with the second main body portion 51 of the second plate 50, the first main body portion 41 of the first plate 40 abuts against the end portion 52a of the second flat plate portion 52 of the second plate 50 to engage with the second flat plate portion 52. With this structure, the first plate 40 and the second plate 50 can be easily positioned, and the assembly performance is improved.

[0080] The first flat plate portion 42 is bent into an L shape relative to the main surface 41a of the first main body portion 41, the flange portion 48 is bent into an L shape relative to the first flat plate portion 42, and the second flat plate portion 52 is bent into an L shape relative to the main surface 51a of the second main body portion 51. With this configuration, the stamping process does not become complicated due to the bending into an L shape.

[0081] The arm body 20 has a curved portion 25, and when viewed from above from a direction intersecting the main surface 41a of the first body 41, the curved portion 25 has a contour curved from the first connection portion 22 toward the inside of the arm body 20. The flange portion 48 is formed on the first flat plate portion 42 located at the curved portion 25. With this configuration, the first plate 40 can improve the rigidity (bending rigidity) of the curved portion 25 extending from the first connection portion 22. In particular, the flange portion 48 can strengthen the rigidity (bending rigidity) of the curved portion 25 near the first connection portion 22.

[0082] The suspension arm 11 of the embodiment further includes a second connection portion 24 to which another component 30 (shaft collar 31) for the vehicle suspension is connected. The arm body portion 20 includes a curved portion 25, which has a contour curved toward the inside of the arm body portion 20 between the first connection portion 22 and the second connection portion 24 when viewed from above from a direction intersecting the main surface 41a of the first body portion 41. The flange portion 48 is formed on the first flat plate portion 42 located at the curved portion 25. With this configuration, the first plate 40 can improve the rigidity (bending rigidity) of the curved portion 25 extending between the first connection portion 22 and the second connection portion 24. In particular, the flange portion 48 can strengthen the rigidity (bending rigidity) near the first connection portion 22 and the rigidity (bending rigidity) near the second connection portion 24 in the curved portion 25. Therefore, without using a support as another component, the left and right rigidity of the arm portion divided into left and right branches with the curved portion 25 sandwiched in the middle can be improved.

[0083] The suspension arm 11 manufactured by the manufacturing method of the embodiment has a first plate 40 and a second plate 50 as stamped products, and has an arm body 20 and a first connecting portion 22 for mounting a component 30 (shaft ring 31) for a vehicle suspension. In order to manufacture the suspension arm 11, first, a first body 41, a first flat plate 42, and a flange 48 are formed on the first plate 40. The first plate 40, which is formed by bending the first flat plate 42, is subjected to stamping processing to form a first mounting surface 43. Similarly, a second body 51 and a second flat plate 52 are formed on the second plate 50. The second plate 50, which is formed by bending the second flat plate 52, is subjected to stamping processing to form a second mounting surface 53. Furthermore, a state is formed in which the first body 41 of the first plate 40 and the second body 51 of the second plate 50 are facing each other. The first plate portion 42 of the first plate 40 and the second plate portion 52 of the second plate 50 are formed to face each other with a gap therebetween, and the first mounting surface 43 and the second mounting surface 53 are arranged with a gap therebetween. Furthermore, the first plate 40 and the second plate 50 are integrated by welding in a state where the flange portion 48 of the first plate 40 is overlapped on the second main body portion 51 of the second plate 50, thereby forming the arm main body portion 20 and the first connecting portion 22.

[0084] According to the manufacturing method of this structure, the rigidity of the first connecting portion 22 can be improved without using other components. Furthermore, even if the axial length of the component 30 (shaft collar 31) is short, it is possible to provide a suspension arm 11 that can form the first connecting portion 22 for installing the component 30 (shaft collar 31) by using a cost-effective stamping process.

[0085] Along the direction in which the flange portion 48 overlaps with the second main body portion 51 of the second plate 50, the first main body portion 41 of the first plate 40 abuts against the end portion 52a of the second flat plate portion 52 of the second plate 50 to be welded to the second flat plate portion 52. This manufacturing method makes it easy to position the first plate 40 and the second plate 50, and the assembly performance is improved. Furthermore, the gap management between the first plate 40 and the second plate 50 is easy, and the welding performance is improved. In addition, the welding of the flange portion 48 and the second main body portion 51 and the welding of the first main body portion 41 and the second flat plate portion 52 can be performed on the same side. Therefore, the welding performance is further improved.

[0086] The first plate 40 is formed by deep drawing a blank 49 to form a first main body portion 41, a first flat plate portion 42, and a bent portion 49a which is continuous with the first flat plate portion 42 and bent relative to the first flat plate portion 42, and then the flange portion 48 is formed by trimming an unnecessary portion of the bent portion 49a. With this manufacturing method, the wall thickness of the bent portion 49a including the portion that will eventually form the flange portion 48 is constant at the end of the deep drawing. Therefore, compared with a sequence in which the flange portion 48 is further bent after the first flat plate portion 42 is formed, it is possible to suppress the generation of cracks at the end of the flange portion 48.

[0087] The first flat plate portion 42 is bent into an L shape relative to the main surface 41a of the first main body portion 41, the flange portion 48 is bent into an L shape relative to the first flat plate portion 42, and the second flat plate portion 52 is bent into an L shape relative to the main surface 51a of the second main body portion 51. According to this manufacturing method, the stamping process does not become complicated due to the bending into the L shape.

[0088] The arm body 20 is formed with a curved portion 25, and when viewed from above from a direction intersecting the main surface 41a of the first body 41, the curved portion 25 has a contour curved from the first connection portion 22 toward the inside of the arm body 20. The flange portion 48 is formed on the first flat plate portion 42 located at the curved portion 25. By this manufacturing method, the first plate 40 can improve the rigidity (bending rigidity) of the curved portion 25 extending from the first connection portion 22. In particular, the flange portion 48 can strengthen the rigidity (bending rigidity) of the curved portion 25 near the first connection portion 22.

[0089] The suspension arm 11 of the embodiment further includes a second connection portion 24 for connecting another component 30 (shaft collar 31) for the vehicle suspension. The arm body portion 20 includes a curved portion 25, and when viewed from above from a direction intersecting the main surface 41a of the first body portion 41, the curved portion 25 has a contour curved toward the inside of the arm body portion 20 between the first connection portion 22 and the second connection portion 24. The flange portion 48 is formed on the first flat plate portion 42 located at the curved portion 25. By this manufacturing method, the first plate 40 can improve the rigidity (bending rigidity) of the curved portion 25 extending between the first connection portion 22 and the second connection portion 24. In particular, the flange portion 48 can strengthen the rigidity (bending rigidity) near the first connection portion 22 and the rigidity (bending rigidity) near the second connection portion 24 in the curved portion 25. Therefore, without using a support as another component, the left and right rigidity of the arm portion divided into left and right branches with the curved portion 25 sandwiched in the middle can be improved.

[0090] Modifications

[0091] The present invention is not limited to the above-described embodiment, and appropriate changes may be made. For example, the vehicle suspension arm 11 is formed of two plates (the first plate 40 and the second plate 50) as described above, but may be formed of three or more plates.

[0092] In the above, the suspension arm 11 is described in which the second connection portion 24 (other connection portion) has the same structure as the first connection portion 22 (connection portion), but the present invention is not limited to this case. The present invention is also applicable to a vehicle suspension structure in which the structure of the second connection portion 24 is different from that of the first connection portion 22.

[0093] Although the suspension arm 11 having the first connection portion 22 and the second connection portion 24 has been described above, the present invention is not limited to this case and can also be applied to a vehicle suspension structure having only the first connection portion 22 and not the second connection portion 24 .

[0094] The above-mentioned embodiment applies the vehicle suspension structure of the present invention to a vehicle suspension arm, but the present invention is not limited to this case. As long as it has a first plate and a second plate as stamped products, and has a main body and a connecting portion for connecting a component for a vehicle suspension, the vehicle suspension structure of the present invention can also be applied to a vehicle suspension assembly.

Claims

1. A vehicle suspension structure, comprising at least a first plate and a second plate as stamped products, and having a main body and a connection portion for connecting a component for a vehicle suspension, characterized in that: The first plate material comprises a first main body portion, a first flat plate portion, a first mounting surface and a flange portion, wherein the first main body portion constitutes the main body portion, the first flat plate portion is continuous on a main surface of the first main body portion and extends in a curved manner relative to the main surface, the first mounting surface is formed on the first flat plate portion and abuts against an outer surface of the constituent component, and the flange portion is continuous on the first flat plate portion and is curved relative to the first flat plate portion and extends outwardly further than the main surface of the first main body portion. The second plate has a second main body, a second flat plate, and a second mounting surface. The second main body and the first main body of the first plate together constitute the main body. The second flat plate is continuous on the main surface of the second main body and extends in a curved manner relative to the main surface. The second mounting surface is formed on the second flat plate and abuts against the outer surface of the constituent component. The first plate has a portion facing the first flat plate portion open so that the first mounting surface can be formed by press working in a state where the first flat plate portion is bent alone. The portion of the second plate facing the second flat plate portion is open so that the second mounting surface can be formed by press working in a state where the second flat plate portion is bent alone. The main body is formed by making the first main body of the first plate and the second main body of the second plate face each other. The connection portion is formed by making the first flat plate portion of the first plate and the second flat plate portion of the second plate face each other with a gap therebetween, and arranging the first mounting surface and the second mounting surface with a gap therebetween. The flange portion of the first plate is overlapped and joined to the second main body portion of the second plate.

2. The vehicle suspension structure according to claim 1, wherein: Along the direction in which the flange portion overlaps with the second main body portion of the second plate, the first main body portion of the first plate abuts against an end portion of the second flat plate portion of the second plate to be joined to the second flat plate portion.

3. The vehicle suspension structure according to claim 1, wherein: The first flat plate portion is bent into an L-shape relative to the main surface of the first main body portion. The flange portion is bent into an L-shape relative to the first flat plate portion, The second flat plate portion is bent into an L-shape with respect to the main surface of the second main body portion.

4. The vehicle suspension structure according to claim 1, wherein: The main body has a curved portion having a contour curved from the connection portion toward the inside of the main body when viewed from above in a direction intersecting a main surface of the first main body, The flange portion is formed on the first flat plate portion located at the bent portion.

5. The vehicle suspension structure according to claim 1, wherein: It also has other connecting parts for connecting other components of the vehicle suspension, The main body has a curved portion having a contour curved toward the inside of the main body between the connecting portion and the other connecting portion when viewed from above in a direction intersecting a main surface of the first main body, The flange portion is formed on the first flat plate portion located at the bent portion.

6. The vehicle suspension structure according to any one of claims 1 to 5, wherein: The vehicle suspension structure is applied to a vehicle suspension arm.

7. A method for manufacturing a vehicle suspension structure, the vehicle suspension structure having at least a first plate and a second plate as stamped products, and having a main body and a connecting portion for connecting a component for a vehicle suspension, characterized in that: A first main body portion, a first flat plate portion, and a flange portion are formed on the first plate material, wherein the first main body portion constitutes the main body portion, the first flat plate portion is continuous on a main surface of the first main body portion and extends in a curved manner relative to the main surface, and the flange portion is continuous on the first flat plate portion and extends outwardly relative to the first flat plate portion. The first plate material, which is the first plate portion bent, is pressed against a die to form a first mounting surface that is in contact with the outer surface of the component on the first plate portion. A second main body and a second flat plate are formed on the second plate, the second main body and the first main body of the first plate together constitute the main body, the second flat plate is continuous on the main surface of the second main body and extends in a curved manner relative to the main surface, The second plate material having the bent second flat plate portion is pressed against the die to form a second mounting surface that is in contact with the outer surface of the component on the second flat plate portion. The first main body portion of the first plate and the second main body portion of the second plate are placed in a state of facing each other, and the first flat plate portion of the first plate and the second flat plate portion of the second plate are placed in a state of facing each other with a gap therebetween, and the first mounting surface and the second mounting surface are arranged with a gap therebetween, and then the flange portion of the first plate is overlapped on the second main body portion of the second plate, and the first plate and the second plate are integrated by welding to form the main body portion and the connecting portion.

8. The method for manufacturing a vehicle suspension structure according to claim 7, wherein: Along the direction in which the flange portion overlaps with the second main body portion of the second plate, the first main body portion of the first plate abuts against the end portion of the second flat plate portion of the second plate to be welded to the second flat plate portion.

9. The method for manufacturing a vehicle suspension structure according to claim 7, wherein: The first plate material is formed by deep drawing a blank into the first main body portion, the first flat plate portion, and a bent portion that is continuous with the first flat plate portion and is bent relative to the first flat plate portion. Then, the flange portion is formed by trimming an unnecessary portion of the bent portion.

10. The method for manufacturing a vehicle suspension structure according to claim 7, wherein: The first flat plate portion is bent into an L-shape relative to the main surface of the first main body portion. The flange portion is bent into an L-shape relative to the first flat plate portion, The second flat plate portion is bent into an L-shape with respect to the main surface of the second main body portion.

11. The method for manufacturing a vehicle suspension structure according to claim 7, wherein: The main body portion is formed with a bent portion having a contour bent from a portion of the connecting portion toward an inner side of the main body portion when viewed from above in a direction intersecting a main surface of the first main body portion. The flange portion is formed on the first flat plate portion located at the bent portion.

12. The method for manufacturing a vehicle suspension structure according to claim 7, wherein: The vehicle suspension structure further includes other connecting parts for connecting other components of the vehicle suspension. The main body portion is formed with a curved portion, and when viewed from above in a direction intersecting a main surface of the first main body portion, the curved portion has a contour curved toward the inside of the main body portion between the connecting portion and the other connecting portion, The flange portion is formed on the first flat plate portion located at the bent portion.

13. The method for manufacturing a vehicle suspension structure according to any one of claims 7 to 12, wherein: The vehicle suspension structure is applied to a vehicle suspension arm.

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