Manufacturing method of assembly

Abstract

To secure a predetermined flatness in a predetermined portion of an assembly including a metal member.SOLUTION: In a first step, a first through hole is formed at a first member. In a second step, in a second member formed of a metal, a protrusion protruding from a surface of the second member and having a size that allows the protrusion to fit in the first through hole is formed. In a third step, the protrusion is fitted in the first through hole. In a fourth step, a part of the protrusion fitted in the first through hole is plastically flowed to fix the plastically flowed portion to a surface on which the first through hole is formed.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present disclosure relates to a method for manufacturing an assembly. [Background technology]

[0002] In the manufacture of machine parts (e.g., automobile parts), it is sometimes necessary to join metal plates together. One known joining method is to fill a through hole provided in a first plate-shaped member with a protrusion by plastically deforming a second plate-shaped member (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 6003232 Summary of the Invention [Problem to be solved by the invention]

[0004] In an assembly including a metal member, ensuring flatness at a predetermined portion is often important.

[0005] An object of the present disclosure is to ensure a predetermined flatness at a predetermined portion of an assembly including a metal member. [Means for solving the problem]

[0006] A first aspect of the present disclosure includes a first step, a second step, a third step, and a fourth step, In the first step, a first through hole is formed in a first member; In the second step, a protrusion is formed on a second member made of metal, the protrusion having a size that protrudes from a surface of the second member and fits into the first through hole; In the third step, the protrusion is fitted into the first through hole, In the fourth step, a part of the protrusion fitted into the first through hole is plastically flowed, and the plastically flowed part is fixed to a surface that forms the first through hole. A method for manufacturing an assembly.

[0007] In the first aspect, the step of forming the protrusion (second step) and the step of fixing the first member and the second member (fourth step) are separate steps, so that the predetermined flatness can be easily ensured at predetermined portions of the first member and the second member in the fourth step.

[0008] In this embodiment, the protrusion is pressed against the surface that defines the first through hole due to plastic flow of a portion of the protrusion. This fixes the first member and the second member to each other. In this embodiment, no joining member is required. In this embodiment, an assembly including a metal member can be easily manufactured.

[0009] A second aspect of the present disclosure provides a method for manufacturing an assembly according to the first aspect, comprising: In the first step, a cross-sectional area of ​​one end of the first through hole is formed smaller than a cross-sectional area of ​​the other end thereof, In the third step, the protrusion is fitted into the first through hole from the one end side. A method for manufacturing an assembly.

[0010] In a second embodiment, the protrusion is crimped near a portion of the first through-hole with a larger cross-sectional area (near the other end). Since the cross-sectional area of ​​one end of the first through-hole is smaller than the cross-sectional area of ​​the other end, the protrusion is less likely to come off from the other end toward the one end. In this embodiment, a greater peel strength can be obtained.

[0011] A third aspect of the present disclosure provides a method for manufacturing an assembly according to the second aspect, comprising: the first member is metal, In the first step, the first through hole is formed by press working, In the third step, the protrusion is fitted into the first through hole from an opening on a side closer to a cut surface that constitutes the first through hole. A method for manufacturing an assembly.

[0012] In a third aspect, the difference in cross-sectional area of ​​the first through hole is formed by press working. In this aspect, the peel strength can be improved at low cost.

[0013] A fourth aspect of the present disclosure provides a method for manufacturing an assembly according to the first or second aspect, comprising: In the first step, a second through hole is formed in a third member; In the third step, One or more of the third members are arranged on top of the second member so that the protrusions pass through the second through holes; The first member is disposed so that the third member is sandwiched between the second member and the first member. A method for manufacturing an assembly.

[0014] In the fourth aspect, joining of multiple members (three or more) is realized using only the members to be joined.

[0015] A fifth aspect of the present disclosure provides a method for manufacturing an assembly according to the first or second aspect, comprising: In the second step, the protrusion is formed by stopping the piercing punch midway without penetrating the second member. A method for manufacturing an assembly.

[0016] The fifth aspect is more advantageous in terms of ensuring the flatness of the second member than when the protrusion is formed by doweling. [Effects of the Invention]

[0017] According to the present disclosure, it is possible to ensure a predetermined flatness at a predetermined portion of an assembly including a metal member. [Brief explanation of the drawings]

[0018] [Figure 1] FIG. 1 is a cross-sectional view showing a schematic configuration of an assembly according to a first embodiment. [Figure 2] FIG. [Figure 3]FIG. [Figure 4] FIG. [Figure 5] 3A to 3C are diagrams illustrating a manufacturing process of an assembly according to the first embodiment. [Figure 6] FIG. 10 is a diagram schematically showing a state in which the plate to be joined and the base plate are set in a press die. [Figure 7] 10A to 10C are diagrams showing the manufacturing process of the assembly in the second embodiment. [Figure 8] 10A to 10C are diagrams illustrating a manufacturing process of an assembly according to a third embodiment. [Figure 9] FIG. 10 is a plan view showing a first modified example of the protrusion. [Figure 10] FIG. 10 is a plan view showing a first modified example of a first through hole. [Figure 11] FIG. 10 is a plan view showing a second modified example of the protrusion. [Figure 12] FIG. 10 is a plan view showing a third modified example of the protrusion. [Figure 13] FIG. 10 is a plan view showing a fourth modified example of the protrusion. [Figure 14] FIG. 10 is a cross-sectional view showing a second modified example of the first through hole. DETAILED DESCRIPTION OF THE INVENTION

[0019] [Embodiment 1] Fig. 1 is a cross-sectional view showing a schematic configuration of an assembly 10 including a metal member in embodiment 1. An example of an application of the assembly 10 is a bracket for a vibration-isolating device (e.g., a vibration-isolating rubber as an automobile part). Fig. 1 shows a portion of the bracket.

[0020] <<Assembly structure>> 1, the assembly 10 includes a plate to be joined 20 (first member) and a base plate 30 (second member). In the assembly 10, the plate to be joined 20 and the base plate 30 are joined to each other.

[0021] The base plate 30 is a component that constitutes the bracket. The base plate 30 is a plate-shaped member. The base plate 30 is made of metal. More specifically, the base plate 30 is made of iron. The base plate 30 has protrusions 31 (also called dowels) that protrude from its surface (plate surface).

[0022] FIG. 2 is a plan view of the protrusion 31. FIG. 3 is a side view of the protrusion 31. These figures show the shape of the protrusion 31 on the single base plate 30 (the shape before being joined to the joined plate 20). As will be described in detail later, the protrusion 31 is formed by press working. As shown in FIGS. 2 and 3, the shape of the protrusion 31 is generally cylindrical. The top of the protrusion 31 is a convex curved surface (see FIG. 3).

[0023] The plate 20 to be joined is a plate-shaped member. The plate 20 to be joined is a component that constitutes the bracket. The plate 20 to be joined is made of metal. More specifically, the plate 20 to be joined is made of iron.

[0024] 4 is a cross-sectional view of the plate to be joined 20. A first through hole 21 is formed in the plate to be joined 20. The cross section of the first through hole 21 perpendicular to the penetration direction is circular. A protrusion 31 is fitted into the first through hole 21. A predetermined portion of the tip of the protrusion 31 (deformed portion 31a described below) is crimped onto a part of the surface that constitutes the first through hole 21 (see FIG. 1). A specific method for crimping will be described later.

[0025] 《Manufacturing of Assembly》 FIG. 5 is a diagram showing the manufacturing process of the assembly 10 in this embodiment. As an example, the assembly 10 can be manufactured by a first step St1 to a fourth step St4 shown in FIG. 5. In other words, the manufacturing method of the assembly 10 includes a first step St1, a second step St2, a third step St3, and a fourth step St4. In the example of FIG. 5, for convenience of explanation, the first step St1 and the second step St2 are performed in this order, but the order in which the first step St1 and the second step St2 are performed is arbitrary. Either the first step St1 or the second step St2 may be performed first. The first step St1 and the second step St2 may be performed simultaneously or in parallel.

[0026] -1st process St1- In the first step St1, the first through hole 21 is formed in the material for the joined plate 20. In the first step St1, the first through hole 21 is formed by press working. Specifically, in the first step St1, the material for the joined plate 20 is pierced using a press molding machine to form the first through hole 21.

[0027] In this embodiment, the minimum width from the outer periphery (edge) of the first through hole 21 to the edge of the joined plate 20 is 1.5 to 2.0 times the plate thickness t1 of the joined plate 20. If trimming is performed on the joined plate 20 after the first through hole 21 is formed, the minimum width can be further reduced.

[0028] The surface constituting the first through hole 21 (hereinafter referred to as the inner peripheral surface S) has a predetermined range on the side where the die (punch) enters during processing as a cut surface S1. On the inner peripheral surface S, the portion continuing to the cut surface S1 in the direction of travel of the punch is a fracture surface S2.

[0029] The diameter at the cut surface S1 is smaller than the diameter at the fractured surface S2, and a step is formed on the inner peripheral surface S. In other words, in the first step St1, the cross-sectional area of ​​one end (the cut surface S1 side) of the first through hole 21 is formed smaller than the cross-sectional area of ​​the other end (the fractured surface S2 side). Here, the cross-sectional area of ​​the first through hole 21 refers to the cross-sectional area in a cross section perpendicular to the penetration direction of the first through hole 21 (the same applies hereinafter).

[0030] In this embodiment, the diameter of the first through hole 21 is determined so that the protrusion 31 can be easily inserted into the first through hole 21. Specifically, the diameter D1 (see FIG. 4) at the cut surface S1 is set to be approximately 0.1 mm larger than the diameter D2 of the protrusion 31 (the value before the fourth step St4 is performed).

[0031] -2nd process St2- In the second process St2, protrusions 31 that protrude from the surface (plate surface) of the material for the base plate 30 are formed. The protrusions 31 are sized to fit into the first through holes 21. Specifically, the protrusions 31 are formed in the material for the base plate 30 using a press molding machine. To form the protrusions 31, a mold having approximately the same shape as the mold used for piercing can be used.

[0032] Specifically, in the second step St2, a piercing (hole-punching) punch 50 (see the two-dot chain line in FIG. 1 ) is stopped midway without penetrating the base plate 30 (second member), thereby forming the protrusion 31. Note that FIG. 1 does not show the die corresponding to the punch 50. In the same manner as when the piercing punch 50 is caused to penetrate (punch) the base plate 30 in the thickness direction, the piercing punch 50 is punched into the base plate 30 from the back side to the front side of the base plate 30. However, the piercing punch 50 is stopped midway without penetrating the base plate 30. The tip of the piercing punch 50 is located behind the front surface of the base plate 30. The piercing punch 50 is stopped just before the base plate 30 breaks.

[0033] The value of the height h of the protrusion 31 is smaller than the value of the plate thickness t2 of the base plate 30. The height h is approximately 2 / 3 of the plate thickness t2. In this example, the value of the height h of the protrusion 31 is smaller than the plate thickness t1 of the plate to be joined 20. However, the height h of the protrusion 31 is set so that the tip of the protrusion 31 is located near the cut surface S1 when the protrusion 31 is inserted into the first through hole 21 (the state after the third step St3 is completed).

[0034] The minimum width W1 (see, for example, FIG. 2) from the outer peripheral surface of the protrusion 31 to the edge of the base plate 30 is 1.5 to 2.0 times the thickness t2 of the base plate 30. If trimming is performed on the base plate 30 after the protrusion 31 is formed, the minimum width W1 can be further reduced.

[0035] -3rd process St3- In the third step St3, the base plate 30 and the plate to be joined 20 are overlapped, and the protrusions 31 are fitted into the first through holes 21. At this time, the direction in which the protrusions 31 are fitted into the first through holes 21 is from the opening on the side closer to the cut surface S1 that constitutes the first through holes 21 (the side of one end of the first through holes 21). In other words, in the first step St1, the pressing direction when forming the first through holes 21 is determined so that the protrusions 31 can be fitted from the opening on the side closer to the cut surface S1. In summary, in the third step St3, the protrusions 31 are fitted into the first through holes 21 from the opening on the side closer to the cut surface S1 that constitutes the first through holes 21 (the side of one end of the first through holes 21).

[0036] In the third step St3, the plate to be joined 20 and the base plate 30 are set in a press mold (more specifically, a mold) while they are overlapped with each other. Fig. 6 is a diagram schematically showing the plate to be joined 20 and the base plate 30 set in the press mold. As shown in Fig. 6, the base plate 30 is placed on a die D and set in the mold so that the tip of the protrusion 31 faces the punch P.

[0037] -4th process St4- In the fourth step St4, a part (mainly the tip) of the protrusion 31 fitted in the first through-hole 21 is plastically flowed (plastically deformed), and the plastically flowed (plastically deformed) portion (hereinafter, deformed portion 31a) is pressed against the inner circumferential surface S (mainly the fracture surface S2). Specifically, the protrusion 31 is pressed with a punch P (see FIG. 6).

[0038] By pressing the protrusion 31 with the punch P, the vicinity of the top of the protrusion 31 expands in the radial direction (undergoes plastic flow). The deformed portion 31a formed in response to this expansion is pressed against the inner circumferential surface S (mainly the fracture surface S2). In this embodiment, since the top of the protrusion 31 is a convex curved surface, the pressing can be performed easily and reliably. When the pressing is completed, the fourth step St4 is completed. When the fourth step St4 is completed, the two plates 20, 30 are fixed to each other.

[0039] Effects of this embodiment For example, suppose two plate-shaped members are stacked on top of each other, and a protrusion is made to protrude from one plate-shaped member into a through-hole in the other plate-shaped member. In other words, suppose the plate-shaped members are fastened together in the process of forming the protrusion (hereinafter, for convenience of explanation, this construction method will be referred to as the conventional construction method).

[0040] In conventional methods, when forming the protrusions, the material around the protrusions is pulled toward the protrusions, deteriorating the flatness around the protrusions. This is because the plate-like members are two-ply, and therefore the area around the protrusions is not sufficiently supported (the plate-like member with the through-holes formed therein is deformed). In conventional methods, the process of forming the protrusions and the process of fixing the protrusions to their counterparts are carried out simultaneously, which may lead to the deterioration of flatness.

[0041] When it is difficult to ensure flatness, it is difficult to create joints in areas adjacent to narrow regions (for example, near the edges or corners of components) or near fastening surfaces using screws, etc., using conventional construction methods.

[0042] In this embodiment, the step of fixing the to-be-joined plate 20 and the base plate 30 (fourth step St4) is a separate step from the step of forming the protrusions 31 (second step St2) and the step of forming the first through holes 21.

[0043] In the second step St2, the protrusion 31 is formed while the material is held by a mold. Therefore, in the second step St2, a predetermined flatness can be easily ensured around the protrusion 31. Similarly, in the first step St1, the first through hole 21 is formed while the material is held by a mold, so that a predetermined flatness can be easily ensured around the first through hole 21.

[0044] If a predetermined flatness is ensured for each of the plate to be joined 20 and the base plate 30, the flatness is maintained well within a predetermined range even when the plates are pressure-bonded together in the fourth step St4. That is, in this embodiment, good flatness can be ensured at predetermined locations of the assembly 10 including the metal members.

[0045] As described above, the joints (protrusions 31, first through holes 21) in this embodiment can be formed in locations adjacent to narrow areas (for example, near edges or corners of members) or near fastening surfaces using screws, etc. The assembly 10 is useful in applications where a joint is required in a location adjacent to a narrow area or near a fastening surface using screws, etc.

[0046] In this embodiment, the assembly 10 can be manufactured using only sheet metal press processing technology. In this embodiment, joining is achieved using only the components to be joined. In this embodiment, additional components for joining (such as rivets or bolts) are not required. In this embodiment, an assembly including metal components can be easily manufactured.

[0047] In this embodiment, the assembly 10 can be easily manufactured even when the plate thicknesses of the plate to be joined 20 and the base plate 30 are different from each other.

[0048] In this embodiment, the assembly 10 can be manufactured whether the joined plate 20 and the base plate 30 are made of the same material or different materials. Examples of combinations of the plates 20, 30 include a steel plate and an aluminum alloy, a steel plate and a copper plate, a steel plate and a stainless steel plate, and a steel plate and a resin material. In this embodiment, the plates 20, 30 can be joined (assembled) even if they are made of materials that cannot be welded to each other.

[0049] In this embodiment, when both plates 20 and 30 are made of the same material (for example, iron), they can be joined even when their mechanical properties (tensile strength, etc.) are different from each other.

[0050] In the assembly 10, the deformed portion 31a is pressed against the fractured surface S2. In the first through-hole 21, the cross-sectional area at the fractured surface S2 is larger than the cross-sectional area at the cut surface S1, so the deformed portion 31a is less likely to come off from the fractured surface S2 in the direction of the cut surface S1. That is, this embodiment makes it easy to improve the strength (peel strength) for peeling the two plates 20, 30 apart. Of course, even in a structure in which the deformed portion 31a is pressed against mainly the cut surface S1, it is possible to design the shape of the protrusion 31 so as to obtain a predetermined peel strength.

[0051] In this embodiment, the peel strength can be easily adjusted by, for example, adjusting the size (diameter and height in this embodiment) and shape of the protrusions 31.

[0052] In this embodiment, the step (difference in cross-sectional area) on the inner circumferential surface S is formed by utilizing the characteristics of press working. Therefore, in this embodiment, the difference in cross-sectional area can be formed inexpensively. As described above, this difference in cross-sectional area contributes to improving peel strength. In other words, in this embodiment, improvement in peel strength can be realized inexpensively.

[0053] In this embodiment, in the second step St2, the punch 50 for piercing (hole punching) is stopped midway without penetrating the base plate 30 (second member), thereby forming the protrusion 31. Since the protrusion 31 is formed on the base plate 30 by the punch 50 for piercing, warpage deformation and the like of the base plate 30 is suppressed compared to when doweling processing (a processing method in which material is poured to form a dowel) is applied, which is advantageous in ensuring the flatness of the base plate 30.

[0054] [Embodiment 2] 7A and 7B are diagrams illustrating the manufacturing process of the assembly 10 in embodiment 2. Fig. 7A and 7B illustrate the manufacturing process when the plate thickness t1 of the joined plates 20 is smaller than the height h of the protrusions 31.

[0055] The first process St1 and the second process St2 shown in the figure are the same as those in the first embodiment. The order in which the first process St1 and the second process St2 are performed is arbitrary. Either the first process St1 or the second process St2 may be performed first. The first process St1 and the second process St2 may be performed simultaneously or in parallel.

[0056] In the third step St3, the protrusion 31 is fitted into the first through hole 21 from the opening on the side closer to the cut surface S1 that constitutes the first through hole 21. In the third step St3, the joined plate 20 and the base plate 30 are set in a state in which they are superimposed on each other in a press molding machine die. In this embodiment, a die (see FIG. 6) having the same configuration as in the first embodiment is used. With both plates 20, 30 set in the die, the protrusion 31 slightly protrudes beyond the plate surface of the joined plate 20 (see FIG. 7).

[0057] In the fourth step St4, the tip of the protrusion 31 fitted in the first through-hole 21 is plastically flowed to pressure-bond the deformed portion 31a (the plastically deformed portion) and the inner circumferential surface S (mainly the fracture surface S2). Specifically, the protrusion 31 is pressed with a punch P (see FIG. 6).

[0058] Also in this embodiment, by pressing the protrusion 31 with the punch P, the deformed portion 31a is formed, and the deformed portion 31a is crimped to the inner peripheral surface S (mainly the fracture surface S2). In this embodiment, since t1 < h, after pressing, the deformed portion 31a slightly protrudes from the plate surface 21a on the fracture surface S2 side of the joined plate 20. Depending on the dimension setting of h, the deformed portion 31a may be completely contained within the first through hole 21. By the completion of the fourth step St4, the two plates 20 and 30 are fixed to each other.

[0059] 《Effects in this embodiment》 As described above, also in this embodiment, after preparing the joined plate 20 provided with the first through hole 21 and the base plate 30 having the protrusion 31, the two are fixed. Therefore, also in this embodiment as in Embodiment 1, a predetermined flatness is ensured at a predetermined part of the assembly 10 including the metal member.

[0060] Also, in the assembly 10, even when the value of the plate thickness t1 of the joined plate 20 is smaller than the value of the height h of the protrusion 31, joining can be achieved only with the members to be joined. Also in this embodiment, the same effects as in Embodiment 1 can be obtained.

[0061] [Embodiment 3] FIG. 8 is a diagram showing the manufacturing process of the assembly 10 in Embodiment 3. FIG. 8 shows the manufacturing process when a plurality of joined plates are provided in the assembly 10.

[0062] In the example of FIG. 8, in addition to the joined plate 20, a joined plate 40 (third member) is provided. The joined plate 40 is made of metal. Specifically, in this example, the joined plate 40 is made of iron. In the example of FIG. 8, the plate thickness of the joined plate 40 is thinner than the plate thickness of the joined plate 20. However, the relationship between the plate thicknesses of the joined plates 20 and 40 can be arbitrary. The relationship between the plate thicknesses can be determined according to, for example, the specifications of the product.

[0063] As an example, the assembly 10 can be manufactured by the first step St1 to the fourth step St4 shown in FIG. 8. The order of the first step St1 and the second step St2 is arbitrary. Either the first step St1 or the second step St2 can be performed first. The first step St1 and the second step St2 can be performed simultaneously or in parallel.

[0064] -1st process St1- In the first step St1, the first through holes 21 are formed in the material for the joined plates 20 in the same manner as in the first embodiment. Specifically, the first through holes 21 are formed by piercing the material for the joined plates 20 using a press molding machine.

[0065] The first process St1 includes a sub-process of forming second through holes 41 in the material for the joined plate 40. In this sub-process, the second through holes 41 are formed by a press molding machine. The direction in which the second through holes 41 are punched during press molding is arbitrary. The second through holes 41 may be punched from either side of the joined plate 40.

[0066] The order of forming the first through hole 21 and the second through hole 41 is arbitrary. Either the first through hole 21 or the second through hole 41 may be formed first. The first through hole 21 and the second through hole 41 may be formed simultaneously or in parallel.

[0067] -2nd process St2- In the second step St2, similarly to the first embodiment, protrusions 31 are formed on the material for the base plate 30 so as to protrude from its surface. In this embodiment as well, the height h of the protrusions 31 is set so that the tips of the protrusions 31 are positioned near the cut surface S1 when the protrusions 31 are inserted into the first through-holes 21 (the state after the third step St3 is completed).

[0068] -3rd process St3- The third step St3 includes sub-steps 1, 2, and 3.

[0069] (1) Sub-process 1 In sub-process 1, one or more plates 40 to be joined (third members) are placed on the base plate 30 (second member) so that the protrusions 31 pass through the second through holes 41. In the example of FIG. 8, there is only one plate 40 to be joined.

[0070] As described above, the punching direction of the second through hole 41 is arbitrary. Depending on the punching direction, the protrusion 31 may be inserted into the second through hole 41 from the cut surface side or from the fracture surface side.

[0071] (2) Sub-process 2 In sub-process 2, the to-be-joined plate 20 is positioned so that the to-be-joined plate 40 (third member) is sandwiched between the base plate 30 (second member) and the to-be-joined plate 20 (first member). In sub-process 2, the protrusion 31 is fitted into the first through-hole 21 from the opening on the side closer to the cut surface S1 that constitutes the first through-hole 21.

[0072] 8, when the plate to be joined 20 is placed, the total thickness T of the plate to be joined 20 and the plate to be joined 40 is greater than the height h of the protrusion 31 (T>h). Therefore, the tip of the protrusion 31 is inside the first through hole 21. Of course, the total thickness T may be equal to or less than the height h of the protrusion 31 (T≦h).

[0073] (3) Sub-process 3 In sub-process 3, the plates to be joined 20, 40 and the base plate 30 are set in a press molding machine (mold) while they are stacked together. In sub-process 3, a mold (see FIG. 6) having the same configuration as in embodiment 1 is used.

[0074] -4th process St4- In the fourth step St4, the tip of the protrusion 31 fitted in the first through-hole 21 is plastically flowed to pressure-bond the deformed portion 31a (the plastically deformed portion) and the inner circumferential surface S (mainly the fracture surface S2). Specifically, the protrusion 31 is pressed with a punch P (see FIG. 6).

[0075] By pressing the protrusion 31 with the punch P, a deformed portion 31a is formed, and the deformed portion 31a is pressed against the inner circumferential surface S (mainly the fracture surface S2). Upon completion of the fourth step St4, the plates to be joined 20, 40 and the base plate 30 are fixed.

[0076] Effects of this embodiment As described above, in this embodiment as well, the plates to be joined 20, 40 each having a through hole and the base plate 30 having the protrusion 31 are prepared and then fixed together. Therefore, in this embodiment as well as in the first embodiment, a predetermined flatness is ensured at a predetermined portion of the assembly 10 including the metal members.

[0077] Furthermore, in the assembly 10, joining is achieved only with the members to be joined, even when the assembly 10 includes a plurality of plates to be joined 20, 40. In this embodiment as well, the same effects as in the first embodiment can be obtained.

[0078] In this embodiment, two or more types of joining are possible depending on the shape design (size setting, etc.) of the joining portion (protrusion 31, first through hole 21). This embodiment can accommodate various combinations, for example, a combination of steel plate, copper plate, and steel plate, or a combination of steel plate, copper plate, and aluminum alloy.

[0079] [Other examples of protrusions and first through holes] The protrusions 31 and the like may have the shapes described below. Examples of the protrusions 31 and first through holes 21 described below may be selected depending on the application of the product, the required peel strength, etc. The shape of the protrusions 31 described below is the shape of the base plate 30 alone (the shape before being joined to the joined plate 20).

[0080] (1) Fig. 9 is a plan view showing a first modified example of the protrusion 31. As shown in Fig. 9, the protrusion 31 of the first modified example has an oval shape in a plan view. Here, a plan view means viewing the plate surface along a line perpendicular to the plate surface (the same applies hereinafter).

[0081] The protrusion 31 of the first modification example has a convex curved surface at its top. The protrusion 31 of the first modification example has a width W2 in the short direction and a width W3 in the long direction. That is, W2 < W3.

[0082] FIG. 10 is a plan view showing a first modification example of the first through hole 21. The first through hole 21 of the first modification example is paired with the protrusion 31 of the first modification example. As shown in FIG. 10, the first through hole 21 of the first modification example has an oval shape in plan view in terms of cross-sectional shape. The first through hole 21 of the first modification example has a width W4 in the short direction and a width W5 in the long direction. That is, W4 < W5.

[0083] In this example, W2 < W4 and W3 < W5. Therefore, the protrusion 31 of the first modification example can be easily inserted into the first through hole 21 of the first modification example.

[0084] The first through hole 21 (elongated through hole) of the first modification example can also be combined with the protrusion 31 (cylindrical protrusion) in FIG. 2. By fitting the cylindrical protrusion 31 into the first through hole 21 (first modification example) of the elongated hole, play in the longitudinal direction of the first through hole 21 can be provided.

[0085] (2) FIG. 11 is a plan view showing a second modification example of the protrusion 31. As shown in FIG. 11, the protrusion 31 of the second modification example is generally quadrilateral in plan view. The protrusion 31 of the second modification example has a convex curved surface at its top. The protrusion 31 of the second modification example can be combined with a first through hole 21 (through hole with a generally quadrilateral cross section) whose plan view and cross-sectional shape are similar to that of this protrusion 31.

[0086] (3) FIG. 12 is a plan view showing a third modification example of the protrusion 31. As shown in FIG. 12, the protrusion 31 of the third modification example is generally triangular in plan view. The protrusion 31 of the third modification example has a convex curved surface at its top. The protrusion 31 of the third modification example can be combined with a first through hole 21 (through hole with a generally triangular cross section) whose plan view and cross-sectional shape are similar to that of this protrusion 31.

[0087] (4) Fig. 13 is a plan view showing a fourth modified example of the protrusion 31. As shown in Fig. 13, the protrusion 31 of the fourth modified example is generally quadrangular in plan view, and recesses 31b are formed on each of a pair of opposing sides. The top of the protrusion 31 of the fourth modified example is a convex curved surface.

[0088] The protrusion 31 of the fourth modified example can be combined with a first through hole 21 (a through hole having a protrusion formed on its inner surface that fits into the recess 31b) that has a cross-sectional shape similar to that of the protrusion 31 in a plan view. In the fourth modified example, a larger area involved in crimping can be secured. Therefore, in the fourth modified example, high peel strength can be obtained.

[0089] (5) Figure 14 is a cross-sectional view showing a second modified example of the first through hole 21. The first through hole 21 of the second modified example has a portion at one end where countersunk processing has been performed (hereinafter, countersunk portion 21b). Inside the first through hole 21 of the second modified example, the countersunk portion 21b has a larger cross-sectional area than the other portions, and a step is formed on the inner peripheral surface S.

[0090] The countersunk portion 21b can be formed, for example, by cutting using a machine or by pressing. The provision of the countersunk portion 21b enables the assembly 10 to obtain a greater peel strength. The peel strength can be adjusted by adjusting the shape (e.g., diameter, depth, etc.) of the countersunk portion 21b.

[0091] [Other embodiments] The application of the assembly 10 is not limited to the bracket exemplified above, and the manufacturing method of the assembly 10 can be applied to the manufacture of various machine parts and the like.

[0092] The material of the base plate 30 is not limited to the exemplified one (iron), but may be any material that can be made to undergo plastic flow.

[0093] The materials of the plates 20 and 40 to be joined are not limited to those exemplified above. Materials other than metals may be used for the plates 20 and 40 to be joined. That is, the assembly 10 may include members other than metals.

[0094] When a plurality of plates to be joined are provided, these plates to be joined may be made of the same material, or plates to be joined made of different materials may be mixed.

[0095] The method for forming the first through hole 21 is not limited to press molding. The method for forming the first through hole 21 may be, for example, cutting by machining. Similarly, the method for forming the second through hole 41 is not limited to press molding. The method for forming the second through hole 41 may be, for example, cutting by machining.

[0096] In any of the embodiments and modifications, the deformed portion 31a may be formed so that a gap occurs between the protrusion and the through holes (first through hole 21 and second through hole 41).

[0097] The dimensions of the protrusion 31 and the first through-hole 21 may be set so that the fitting between them is a press fit.

[0098] There may be provided a plurality of pairs of protrusions 31 and corresponding first through holes 21. This can improve peel strength.

[0099] A step of providing other components (for example, vibration-proof rubber) on the plate to be joined 20 or the base plate 30 may be added before the fourth step St4.

[0100] If the assembly 10 needs to be painted, the painting may be performed before or after the fourth step St4. [Industrial Applicability]

[0101] The present disclosure is useful as a method for manufacturing an assembly including a metal member. [Explanation of symbols]

[0102] 10 assembly 20 Plate to be joined (first member) 21 First through hole 30 Base plate (second member) 31a Deformed part 40 Plate to be joined (third member) 41 Second through hole 50 Piercing punch S Inner surface (surface that forms the first through hole) S1 cutting surface

Claims

1. The method includes a first step, a second step, a third step, and a fourth step, In the first step, a first through hole is formed in a first member; In the second step, a protrusion is formed on a second member made of metal, the protrusion having a size that protrudes from a surface of the second member and fits into the first through hole; In the third step, the protrusion is fitted into the first through hole; In the fourth step, a part of the protrusion fitted into the first through hole is plastically flowed, and the plastically flowed part is fixed to a surface that forms the first through hole. A method for manufacturing an assembly.

2. 2. The method for manufacturing an assembly according to claim 1, In the first step, a cross-sectional area of ​​one end of the first through hole is formed smaller than a cross-sectional area of ​​the other end thereof, In the third step, the protrusion is fitted into the first through hole from the one end side. A method for manufacturing an assembly.

3. 3. The method for manufacturing an assembly according to claim 2, the first member is metal, In the first step, the first through hole is formed by press working, In the third step, the protrusion is fitted into the first through hole from an opening on a side closer to a cut surface that constitutes the first through hole. A method for manufacturing an assembly.

4. The method for manufacturing an assembly according to claim 1 or 2, In the first step, a second through hole is formed in a third member; In the third step, One or more of the third members are arranged on top of the second member so that the protrusions pass through the second through holes; The first member is disposed so that the third member is sandwiched between the second member and the first member. A method for manufacturing an assembly.

5. The method for manufacturing an assembly according to claim 1 or 2, In the second step, the protrusion is formed by stopping a piercing punch midway without penetrating the second member. A method for manufacturing an assembly.

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