JP2010195317A - Structural member and method for manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a lightweight suspension arm capable of obtaining the predetermined dimensional accuracy at a small part, and sufficiently ensuring the strength against the torsion while it is easily manufactured in order to solve problems including a problem that one end side of the suspension arm is requested to be small for the connection to a vehicle body. <P>SOLUTION: At least on one end side of a square tubular member, a slit-like cutout 15 is formed in upper and lower sides from the end along the longitudinal direction, and uneven shapes 17 opposite to each other in the shorter side direction of the upper and lower sides are formed in the cutout 15. The square tubular member is pressed to form a closed section so that any space formed by the cutout 15 is filled, and the uneven shapes 17 are shrink-fitted or attached to each other to obtain a suspension arm in which at least one end side is contracted. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a structural member suitable for use in, for example, a suspension arm of an automobile and a manufacturing method thereof.

Recently, the market demand for such CO ₂ reduction in the automotive industry reduced vehicle weight is determined, the vehicle component of the suspension arm such was conventional iron is aluminized (hereinafter, aluminized) or magnesium reduction (hereinafter, Magne )) Is being promoted. These light alloys have higher material costs than iron, but a hollow coarse material can be produced at low cost by extrusion. Therefore, a method of forming a hollow extruded material without welding as a method for producing an inexpensive and light aluminum or magne member is considered to be one of the most excellent methods for forming vehicle parts.

  Here, for example, in automobiles, there are suspension systems such as a multi-link system and a double wishbone system. The suspension arm in such a system requires a wide area larger than the diameter (end part) of the coil spring at the part (seat surface) that receives the coil spring of the shock absorber, whereas the vehicle body and knuckle at both ends are required. The attachment portion may be required to be formed small in accordance with the size of the bush to be fastened.

  When forming the suspension arm as described above with a hollow extruded material, there are a method of forming the bush part separately and welding, a method of contracting the attachment parts at both ends, or a method of expanding the seat surface of the coil spring. Conceivable.

  However, the welding method is costly, and in the case of aluminum, there arises a problem of distortion due to heat of fusion and a decrease in material strength. Further, in the method of expanding the tube, there is a case where the strength of the seating surface of the coil spring that is required to have high strength cannot be ensured because it involves thinning.

  Therefore, when the above suspension arm is formed with a hollow extruded material, a method of contracting both ends is preferable. As a method of reducing the tube, a method of directly crushing from both side surfaces with a press, a punched center or a center of the short direction of the portion to be reduced or punched into a slit along the longitudinal direction, and then both sides A method of crushing from the surface is conceivable. Further, Patent Document 1 discloses a method in which the thickness of the upper and lower surfaces forming the closed sectional view space is made thinner than the thickness of both side surfaces when the knuckle side end portion of the suspension arm is contracted, and the both sides are crushed. Is described.

International Publication No. 01/32979 Pamphlet

  As described above, the method of crushing from both sides with a press and shrinking the end portion is difficult to maintain accuracy because the deformation position is not stable. Since the bush mounting portion of the suspension arm is required to have high dimensional accuracy, it is difficult to satisfy such a requirement by this method.

  On the other hand, in the technique described in Patent Document 1, the thickness of the upper and lower surfaces forming the sectional view closed space is made thinner than the thickness of both sides, so that the deformation point is controlled to the central portion of the upper and lower surfaces. It can be formed into any shape. However, in the technique described in Patent Document 1, the strength of the upper and lower surfaces of the suspension arm is insufficient, and the bending force (torsional force) centered on the longitudinal direction of the arm, the vertical force from the coil spring In some cases, sufficient strength could not be secured.

  Therefore, in order to stabilize the accuracy of the bush mounting part while ensuring sufficient strength, the central part in the short direction of the part to be contracted (typically the upper and lower surfaces) is pressed into a slit shape along the longitudinal direction. It is considered that the method of pressing from both sides after punching out or cutting with the method is optimal. However, in this method, since the pressed and butted portion is linear, when a force in the twisting direction is generated on the suspension arm, the butted portions slide up and down with respect to each other. However, there was a problem that the butt portion was worn and the butt portion was worn.

  The present invention has been made in view of such a problem. For example, in a structural member such as a suspension arm that requires at least one end to be contracted, it is lightweight and has a certain size at a contracted site. An object is to ensure sufficient strength against torsion and the like while being able to obtain accuracy and easy to manufacture.

In the structural member of the present invention, at least at one end side in the longitudinal direction of the rectangular tubular member, a notch is formed along the longitudinal direction from the end on the upper surface and the lower surface or opposite side walls, and is formed by the notch. A structural member that is contracted by being pressed so as to fill the formed gap, and in the notch, the upper and lower surfaces or the concave and convex shapes facing each other in the lateral direction of the both side walls are formed. The gap formed by the notch is filled in a state in which the concavo-convex shape is closely fitted or fitted to each other.
In addition, an automobile according to the present invention includes the structural member described above as a suspension arm.
Further, in the manufacturing method of the structural member of the present invention, at least at one end side in the longitudinal direction of the rectangular tubular member, when forming a notch along the longitudinal direction from the end portion on the upper surface and the lower surface, or both side walls, In the cutout, the step of forming the concave and convex shapes facing each other in the short side direction of the upper and lower surfaces or both side walls, and the gap formed by the cutout are filled, and the concave and convex shapes are tightly fitted to each other. Or a step of pressing the rectangular tubular member so as to be fitted, and obtaining a structural member having at least one end of which is contracted.

  According to the present invention, for example, in a structural member that is required to be contracted at least at one end, such as a suspension arm, the light weight, a certain dimensional accuracy is obtained at a site to be contracted, and manufacturing is easy. As a result, sufficient rigidity against torsion can be ensured, and further, wear due to torsion can be suppressed.

It is the figure which showed typically the suspension apparatus which used the suspension arm for motor vehicles based on the 1st Embodiment of this invention as a structural member. It is a perspective view of the lower arm which concerns on the 1st Embodiment of this invention. It is a figure for demonstrating the basic manufacturing method of the lower arm which concerns on the 1st Embodiment of this invention, and is the figure which showed the state which formed the notch etc. in the coarse material for forming a lower arm. It is a figure for demonstrating the basic manufacturing method of the lower arm which concerns on the 1st Embodiment of this invention, and is a transversal direction (the AA cross section shown in FIG. 3) of the coarse material end side for forming a lower arm FIG. It is a figure for demonstrating the basic manufacturing method of the lower arm which concerns on the 1st Embodiment of this invention, and is the figure which showed a mode that the coarse material for forming a lower arm was pressed from both sides. It is the figure which showed the state which formed the notch which has an uneven | corrugated shaped part in the coarse material for forming the lower arm which concerns on the 1st Embodiment of this invention. It is sectional drawing in the transversal direction (BB cross section shown in FIG. 6) of the approximate center part of the rough material for forming the lower arm which concerns on the 1st Embodiment of this invention. It is sectional drawing in the transversal direction (CC cross section shown in FIG. 6) of the site | part in which the notch of the rough material for forming the lower arm which concerns on the 1st Embodiment of this invention was formed. It is the figure which showed the uneven | corrugated shaped part in the notch of the rough material for forming the lower arm which concerns on the 1st Embodiment of this invention. It is the figure which showed a mode that the rough material for forming the lower arm which concerns on the 1st Embodiment of this invention was pressed from both sides. It is sectional drawing of the cross section (DD cross section shown in FIG. 10) when the rough material for forming the lower arm which concerns on the 1st Embodiment of this invention is pressed from both sides. It is the figure which showed the state which formed the penetration hole for attaching a bush to the side wall by the side of the front end of the contraction pipe part of the lower arm which concerns on the 1st Embodiment of this invention. The cross section (EE cross section shown in FIG. 12) at the time of expanding and crimping after inserting an outer cylinder in the side wall at the front end side of the contracted tube portion of the lower arm according to the first embodiment of the present invention is shown. FIG. It is the figure which showed the modification of the lower arm which concerns on the 1st Embodiment of this invention. It is the figure which showed the modification of the lower arm which concerns on the 1st Embodiment of this invention. It is a figure for demonstrating the various parameters used for the experiment about the lower arm which concerns on embodiment of this invention. It is the figure which showed the experimental result of the experiment about the lower arm which concerns on embodiment of this invention. It is a figure shown about the lower arm which concerns on the 2nd Embodiment of this invention, and is the figure which showed what changed the shape of the adjacent convex part or recessed part in an uneven | corrugated shaped part.

  Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings.

<First Embodiment>
(About suspension system)
FIG. 1 is a diagram schematically showing a suspension apparatus using a suspension arm for an automobile according to a first embodiment of the present invention as a structural member.

  In the present embodiment, the suspension device 1 shown in FIG. 1 is configured by a so-called multi-suspension system. In other words, the wheel composed of the tire 2 and the wheel 3 to which the tire 2 is attached is rotatably supported by the knuckle 4, and the knuckle 4 is swingably supported by the vehicle body structural member 5 forming the skeleton of the vehicle body by a plurality of links. The plurality of links include a lower arm 10 as an automobile suspension arm that connects the knuckle 4 and the vehicle body structure member 5 on the lower side of the vehicle, an upper arm 6 that connects the knuckle 4 and the vehicle body structure member 5 on the upper side of the vehicle, A plurality of link members (not shown) are included.

  The vehicle body structural member 5 extends in both the vehicle width directions, and the pair of left and right lower arms 10 are disposed along the vehicle body structural member 5. The lower arm 10 is supported such that one end thereof is swingable near the center of the vehicle body structure member 5 in the vehicle width direction, and the other end is connected to the knuckle 4. A bush 11 is integrally attached to an end of the lower arm 10 on the vehicle body structural member 5 side, and the lower arm 10 is supported by the vehicle body structural member 5 via the bush 11 so as to be swingable. An insertion hole 12 is formed at the end of the lower arm 10 on the knuckle 4 side, and the lower arm 10 is fixed to the knuckle 4 with a bolt or the like through the insertion hole 12. Here, the vehicle body structural member 5 side of the lower arm 10 is formed to be narrower than the knuckle 4 side due to the mounting of the bush 11 and the restriction of the connection space of the vehicle body structural member 5.

  Further, a coil spring 7 of a shock absorber is mounted between the vehicle body structural member 5 and the lower arm 10 along the vertical direction (may be disposed obliquely). Thus, the input received by the wheels from the road surface is mitigated from being transmitted to the vehicle body, so that the stability and ride comfort of the vehicle body are improved. Here, since the lower arm 10 receives the coil spring 7 at the middle part in the longitudinal direction, the lower arm 10 is formed wider than the vehicle body structural member 5 side.

(About the lower arm in the suspension system)
FIG. 2 is a perspective view of the lower arm 10 as the automobile suspension arm according to the first embodiment of the present invention. In the present embodiment, the lower arm 10 is formed of an extruded material (square tubular member) obtained by extruding an aluminum alloy into a square tube shape. Hereinafter, the configuration of the lower arm 10 will be described with reference to FIG.

  First, on the connection side with the knuckle 4, slit-shaped notches are formed along the longitudinal direction from the end portions on the upper surface and the lower surface, and insertion holes 12 are formed on both side walls connecting the upper surface and the lower surface. As described above, the lower arm 10 is connected to the knuckle 4 by the insertion hole 12.

  Next, a coil spring support portion 13 for receiving one end of the coil spring 7 is provided at substantially the center in the longitudinal direction of the lower arm 10. The coil spring support portion 13 is required to have a sufficient area for fixing the coil spring 7 and a strength against the reaction force of the coil spring 7, and is therefore wide in the short direction, and its closed cross section. Is set so as to have a large cross section so that the area is sufficiently rigid.

  On the other hand, the lower arm 10 is formed narrower than the vicinity of the coil spring support portion 13 on the connection side with the vehicle body structural member 5. Hereinafter, this narrow portion is referred to as a contracted tube portion 14. In the lower arm 10, such a reduced tube portion 14 is formed because a small cross section is required due to restrictions on the arrangement space on the vehicle body configuration such as matching to the size of the bush 11 to be fastened to the vehicle body structural member 5, and lightweight. This is due to the fact that it is required to be made. The lower arm 10 is connected to the vehicle body structural member 5 by the bush 11 as described above.

  As a method of forming the narrowed tube portion 14 on the vehicle body structural member 5 side of the lower arm 10 to make it narrower, first, slit-shaped notches 15 are formed on the upper and lower surfaces of the lower arm 10 along the longitudinal direction from the end portion. To do. Thereafter, the lower arm 10 is pressed (pressed) from both sides to be plastically deformed so as to fill the gap formed by the notch 15, and a part of the lower arm 10 formed by the notch 15 is abutted in the width direction. This is done by using a closed cross section.

  Here, in the lower arm 10 according to the present embodiment, a plurality of recesses and protrusions facing the edge in the width direction of the notch 15 (hereinafter referred to as the notch edge portion 16) in the width direction (short direction). An uneven portion 17 having a portion is formed. The concavo-convex shape portion 17 is formed integrally with the notch 15 and, when pressed from both sides and abutted against each other, is tightly fitted or fitted to each other as shown in FIG. Thereby, in the lower arm 10, the vertical sliding of the notch edge 16 on the upper surface and the lower surface formed by the notch 15 is suppressed, and the strength against the force in the torsional direction is improved.

  A bush 11 is attached to the side wall on the distal end side of the contracted tube portion 14. More specifically, insertion holes 18 (FIG. 12) are formed in both side walls on the distal end side of the contracted tube portion 14, and a bush 11 that is a vehicle body side connection portion is attached so as to be inserted therethrough. In the insertion hole 18, an outer cylinder 19 that is fitted into the insertion hole 18 and a rubber material 20 for holding or fixing the bush 11 in the outer cylinder 19 are disposed around the bush 11. The outer cylinder 19 is fixed so as to give a force to the inside through the insertion hole 18 by being expanded and caulked so that the notch edge 16 formed by the notch 15 is firmly coupled. ing. Further, the rubber material 20 is press-fitted or the like so as to fill a space between the outer cylinder 19 and the bush 11, and attaches and holds the bush 11 substantially at the center of the insertion hole 18.

  As described above, in the lower arm 10 according to the present embodiment, the strength against torsion is improved by forming the concavo-convex shape portion 17 and caulking the outer cylinder 19 with a square tube. Below, the manufacturing method of the lower arm 10 which concerns on this Embodiment is demonstrated.

(About the manufacturing method of the lower arm in the suspension device)
A method for manufacturing the lower arm 10 will be described. As described above, the lower arm 10 is formed of an extruded material (hereinafter referred to as a coarse material) obtained by extruding an aluminum alloy into a square tube shape. The lower arm 10 is manufactured through a process such as bending, cutting, drilling, pressing, or cutting from the state of a rough material.

  First, the outline | summary about manufacture of the lower arm 10 is demonstrated. FIG. 3 is a view showing a state in which a notch or the like is formed in the rough material 30 for forming the lower arm 10. The coarse material 30 shown in FIG. 3 is a rectangular tubular member in which an upper surface and a lower surface and two side walls are integrally coupled.

  First, slit-shaped notches 31 are formed on the upper surface and the lower surface on one end side in the longitudinal direction of the elongated coarse material 30 from the end portion along the longitudinal direction. The notch 31 is formed so that the contracted tube portion 32 formed after this step satisfies a certain dimensional accuracy.

  FIG. 4 is a cross-sectional view in the short-side direction (cross section AA shown in FIG. 3) on the one end side of the coarse material 30. As also referred to in FIG. 4, the rough material 30 is a rectangular tube having a rectangular shape in cross section, and a slit-shaped notch 31 is formed along the longitudinal direction (the direction orthogonal to the paper surface) from the end. Recognize. Note that the coarse material 30 may not be strictly rectangular in cross-sectional view, and may be, for example, one having slightly rounded corners.

  Next, FIG. 5 is a view showing a state where the rough material 30 formed with the notches 31 is pressed from both sides. That is, the upper surface and the lower surface of the rough material 30 divided by the notch 31 are pressed from both sides (FIG. 5, arrows) to form a closed cross section, thereby forming a small section 32 of a reduced cross section. In this way, when the notch 31 is formed and pressed from both sides, the contracted tube portion 32 that satisfies a certain dimensional accuracy can be formed.

  Here, as shown in FIG. 5, when the closed tube section 32 shown in the figure is formed so as to fill the notch 31 by pressing from the state shown in FIG. The contracted tube portion 32 can be formed so as to satisfy, but the notch edge portion 33 formed by the notch 31 and facing in the width direction is pressed linearly. Therefore, the vertical movement of the notched edge 33 is not suppressed when receiving a force in the twisting direction.

  Therefore, in the lower arm 10 according to the present embodiment, the concavo-convex shape portion 17 is formed so as to firmly bond both side surfaces of the notched edge portions opposed in the width direction. Hereinafter, the detail of the manufacturing method of the lower arm 10 concerning this Embodiment is demonstrated.

  FIG. 6 is a view showing a state in which the notch 15 having the concavo-convex shape portion 17 is formed in the rough material 60 for forming the lower arm 10.

  In the present embodiment, first, as shown in FIG. 6, the concave and convex portion 17 is formed simultaneously with the formation of the notch 15. Here, the notch 15 and the concavo-convex shape portion 17 are simultaneously formed by punching with a press, but may be formed by cutting instead. In addition, before or after the formation of the notch 15 and the uneven portion 17 described above or in parallel, slit-like notches are formed on the upper surface and the lower surface on the connection side with the knuckle 4 from the end along the longitudinal direction. An insertion hole 12 for connection to the knuckle 4 is formed in both side walls that are formed and connect the upper surface and the lower surface. In addition, the insertion hole 12 is a connection part with the knuckle 4.

  Here, FIG. 7 is a cross-sectional view in the short direction (BB cross section shown in FIG. 6) in the substantially central portion in the longitudinal direction of the coarse material 60, and FIG. 8 formed the notch 15 of the coarse material 60. It is sectional drawing in the transversal direction (CC cross section shown in FIG. 6) of a side. After the formation of the notch 15 and the concavo-convex shape portion 17, as shown in FIG. 7, the portion of the rough material 60 where the notch 15 is not formed becomes a closed cross section having a rectangular shape in cross section, whereas as shown in FIG. 8. In addition, the portion where the notch 15 is formed has an open cross section when viewed in cross section. In the following description, the upper surface of the rough material 60 will be described as the upper lateral rib 10A, the lower surface as the lower lateral rib 10B, the left side wall of the paper surface as the side wall 10C, and the right side of the paper surface as the side wall 10D.

  FIG. 9 is a view showing the uneven portion 17 in the notch 15. As shown in FIG. 9, in the present embodiment, the concavo-convex shape portion 17 is formed so that the wave-like, that is, the arc-shaped convex portions and the arc-shaped concave portions are arranged in a staggered manner on the longitudinal opening side of the notch 15. It is formed so that the convex portion and the concave portion are opposed to each other in the width direction (short direction) of the upper surface lateral rib 10A and the lower surface lateral rib 10B. In other words, the arc-shaped convex part and the arc-shaped concave part are formed so as to be opposed to each other so as to be attached to the notch edge 16 of the upper surface lateral rib 10A and the lower surface lateral rib 10B formed by the notch 15. The Moreover, in this Embodiment, it becomes the shape by which the convex part and recessed part which oppose in the width direction are formed continuously 4 pairs alternately. Hereinafter, as shown in FIG. 9, the convex portions 17A1, 17B1, 17C1, and 17D1 are formed in order from the opening side, and the concave portions 17A2, 17B2, 17C2, and 17D2 are formed.

  Furthermore, in the present embodiment, the height of the convex portions and the depth of the concave portions, and the radius of the convex portions and the radius of the concave portions included in the concavo-convex shape portion 17 are formed so as to satisfy predetermined dimensional conditions, respectively. Is done. In addition, the reference | standard of the height of a convex part and the depth of a recessed part is the flat surface of the notch edge part 16 which becomes a straight line when it is faced, in other words, the longitudinal direction of the both sides of the notch 15 A flat surface along. Here, the dimensional condition of the convex portion and the concave portion is a condition for the convex portion and the concave portion to be tightly fitted or fitted (that is, press-fitted) and firmly bonded in a subsequent process. In the following, as shown in FIG. 9, the height of the convex portions 17A1, 17B1, 17C1, 17D1 is Ha, the depth of the concave portions 17A2, 17B2, 17C2, 17D2 is Hb, and the convex portions 17A1, 17B1, 17C1, 17D1 The radius is Ra, and the radius of the recesses 17A2, 17B2, 17C2, and 17D2 is Rb.

In the present embodiment, as an example of the predetermined dimensional condition described above, the ratio of the height of the convex portion and the depth of the concave portion facing each other is expressed as “height of convex portion (Ha) / depth of concave portion (Hb) = 1 ”, and the ratio of the radius of the convex portion and the concave portion facing each other is“ the radius of the convex portion (Ra) / the radius of the concave portion (Rb) = 1.1 ”.
That is, between the convex portions 17A1, 17B1, 17C1, and 17D1 and the concave portions 17A2, 17B2, 17C2, and 17D2, “the height of the convex portion (Ha) / the depth of the concave portion (Hb) = 1”, and The concavo-convex shape portion 17 is formed so that the relationship of “convex radius (Ra) / concave radius (Rb) = 1.1” is satisfied. FIG. 9 shows an example in which the height of the convex portion and the depth of the concave portion included in the concavo-convex shape portion 17 are all the same, the radius of the convex portion is the same, and the radius of the concave portion is the same. As long as the above-described predetermined condition is satisfied by a pair of convex portions and concave portions facing each other, the shapes (sizes) of the adjacent convex portions and concave portions may be different. Details of this will be described later.

  Next, FIG. 10 is a diagram showing a state in which the coarse material 60 is pressed from both sides, and FIG. 11 is a cross-section when the coarse material 60 is pressed from both sides (DD cross section shown in FIG. 10). FIG.

  After forming the notch 15 and the concavo-convex shape portion 17 as described above, the narrow contraction portion 14 is formed. The contracted tube portion 14 is pressed, that is, pressed from both sides of the lower arm 10, that is, the side wall 10 C and the side wall 10 D in this case, to plastically deform the side wall 10 C and the side wall 10 D, and beside the upper surface formed by the notch 15. It is formed by abutting the notched edges 16 of the rib 10A and the lower lateral rib 10B.

  Here, in the present embodiment, when the notch edge portion 16 is abutted so as to fill the gap formed by the notch 15, an uneven shape portion including a plurality of opposed convex portions and concave portions at a part thereof. Since 17 is formed, they are pressed (pressed) so that they fit tightly or fit. Thereby, since the convex part and recessed part which oppose are couple | bonded firmly, the vertical motion in the notch edge part 16 is suppressed. In addition, as shown in FIG. 11, after the site | part in which the notch 15 was formed was pressed from both sides, the vehicle body structural member 5 side of the rough material 60 becomes a closed cross section.

  FIG. 10 shows the length L in the longitudinal direction of the butted portion at the notch edge 16 and the length T in the longitudinal direction of the concavo-convex shape portion 17. In addition, the butting part in the notch edge part 16 shall say the area | region including the part which the part which the convex part and recessed part of the uneven | corrugated shaped part 17 are butt-fit or fitted on a straight line. As for the relationship between the butted portion of the notched edge 16 and the uneven shape portion 17, if the uneven shape portion 17 is less than the butted portion of the notched edge portion 16 or is short in the longitudinal direction, the coupling is insufficient. It becomes. On the other hand, when there is no portion that abuts on the straight line in the abutting portion of the notched edge portion 16, there is a relationship that the accuracy of the abutting can be unsatisfactory. Therefore, as a result of sharp research, the inventor of the present application has confirmed through experiments that “0.5 <T / L <0.95” is optimal as a range where a strong bond can be obtained and matching can be performed with high accuracy. I found it. Therefore, in the lower arm 10 according to the present embodiment, the notch 15 and the concavo-convex shape portion 17 are formed and pressed so that the T / L relationship is within the above range.

  FIG. 11 shows the thickness t of the upper side lateral rib 10A of the lower arm 10 (note that the lower side lateral rib 10B has the same thickness t). In the above description, the dimensional condition (ratio) of the radius of the convex part and the concave part in the concavo-convex shape part 17 has been described. In the present embodiment, these actual dimensions are selected optimally in relation to the thickness t. To decide. For example, if the radius of the convex portion and the concave portion is too small or too large with respect to the wall thickness t, a strong bond cannot be obtained or the fitting accuracy is lowered. In view of such a point, the present inventor has determined that “t / 2 <radius of projection (Ra) <2t” as a range in which strong bonding is obtained as a result of sharp research and accurate matching is possible. Was found to be optimal through experiments. Therefore, in the lower arm 10 according to the present embodiment, the notch 15 and the uneven shape portion 17 are formed and pressed so that the radius of the convex portion is within the above range.

  Next, FIG. 12 is a view showing a state in which an insertion hole 18 for attaching the bush 11 is formed in the side wall 10C, 10D on the distal end side of the contracted tube portion 14. After the contraction tube portion 14 is formed by pressing, an insertion hole 18 is formed. The insertion hole 18 is formed by cutting or the like, and has the same diameter on the side walls 10C and 10D.

  The bush 11 is inserted into the insertion hole 18. The bush 11 is held via a rubber material 20 in an outer cylinder 19 having a larger diameter than the bush. When the bush 11 is inserted into the insertion hole 18, the bush 11, the outer cylinder 19, and the rubber material 20 are assembled and inserted as a unit. The outer diameter of the outer cylinder 19 is substantially the same as the inner diameter of the insertion hole 18, and when inserted, the outer cylinder 19 is in a loosely fitted state. After the outer cylinder 19 is inserted, the both ends of the outer cylinder 19 are at least partially expanded outward and in close contact with the insertion hole 18. That is, the outer cylinder 19 is subjected to expanded caulking. FIG. 13 is a cross-sectional view showing a cross section (the EE cross section shown in FIG. 12) when the outer cylinder 19 is inserted into the insertion hole 18 and then the expanded tube is caulked. The arrows shown in FIG. 13 indicate the direction of square tube caulking. The expanded caulking for the outer cylinder 19 need not be applied to the entire circumference of both ends of the cylinder, but may be applied at least partially.

  When the outer cylinder 19 is crimped in this manner, a force that pushes the abutting portion of the notched edge portion 16 from the side wall 10C side and the side wall 10D side is generated, and therefore the force that is constantly pressed against the uneven shape portion 17 is generated. As a result, the notched edge 16 is firmly bonded. As a result, the vertical movement at the notch edge 16 is suppressed, and the rigidity against torsion is further improved and the wear is further reduced.

  As described above, the lower arm 10 according to the present embodiment shown in FIG. 2 is manufactured. When the purpose is to suppress the vertical movement at the notched edge 16, only the outer cylinder 19 may be inserted into the insertion hole 18 as shown in FIG. Further, in this case, the outer cylinder 19 may be used as a bush for connection with the vehicle body structural member 5, and in this way, the tight connection of the contracted tube portion 14, the lower arm 10 and the vehicle body structural member 5. Can be obtained at the same time, and an increase in the number of parts can be suppressed. Further, as shown in FIG. 15, the insertion hole 18 may be formed small (18 '), and the side wall 10C and the side wall 10D may be sandwiched by bolts and nuts. Can be achieved.

(About the dimensional condition of the uneven part of the lower arm)
As described above, the lower arm 10 according to the present embodiment is formed. Next, the experimental result about the optimal dimension conditions of the uneven | corrugated shaped part 17 is demonstrated below.

  In the above-described embodiment, as an example of the dimensional condition in the concavo-convex shape portion 17, the ratio of the height of the convex portion and the concave portion facing each other is “the height of the convex portion / the depth of the concave portion = 1”, and the convex portion facing each other. It was explained that the ratio of the radius of the concave portion to the radius of the convex portion / radius of the concave portion = 1.1. Below, the result of having manufactured the lower arm 10 mentioned above on various conditions different from this condition, and having performed the butt test and the torsional durability test about it is shown.

  FIG. 16 is a diagram for explaining various parameters used in the experiment. In FIG. 16, L1 and L2 indicate reference positions for the height of the convex portion and the depth of the concave portion. That is, the reference positions L1 and L2 are flat surfaces of the cut-out edge portion 16 that are linear when they are abutted, or flat surfaces along the longitudinal direction on both sides of the cut-out 15. Ha represents the height of the convex portion, hb represents the depth of the concave portion, Ra represents the radius of the convex portion, and Rb represents the radius of the concave portion. In this experiment, all the convex portions have the same radius Ra, and all the concave portions have the same radius Rb in each experiment.

  Further, in this experiment, the lower arm 10 is formed of a 6000 series aluminum extruded material, and the wall thickness is 4 mm. Further, in the experiment here, as the butt test, it is verified whether or not the opposing convex and concave portions can be tightly fitted or fitted, and as the torsional durability test, the lower arm 10 is twisted in a torsional direction of 10 degrees. It was verified whether or not wear occurred when the force was applied 100,000 times.

  FIG. 17 shows the experimental results. As shown in FIG. 17, in this experiment, the conditions of the height Ha of the convex portion, the depth Hb of the concave portion, the radius Ra of the convex portion, and the radius Rb of the concave portion were 12 types (Test Nos. 1 to 12). In FIG. 17, “OK” is shown when the fit or the fit is made in the butt test, and “NG” is shown when the fit is not possible. In the torsional durability test, “OK” is indicated when no wear occurs, and “wear” is indicated when wear occurs.

  Referring to FIG. 17, in Test Nos. 5, 6 and 12, the convex portion and the concave portion could not be tightly fitted or fitted (hereinafter, tightly fitted or the like). From these results, it was found from Test Nos. 5 and 6 that if the radius of the concave portion is too small compared to the radius of the convex portion, an interference fit or the like cannot be achieved. On the other hand, considering the results of Test No. 4 and Test Nos. 7 to 12 and processing accuracy such as dimensional tolerances, it is determined that “Ra / Rb <1.2” is optimal as the ratio of the radius of the convex portion and the concave portion to be paired. did it. In addition, when the radius of the concave portion is larger than the radius of the convex portion, of course, it is not possible to perform an interference fit or the like. It was found that “1 ≦ Ra / Rb” may be satisfied.

  In addition, it can be seen from Test No12 that if the height of the convex part is too higher than the depth of the concave part, it is not possible to perform an interference fit or the like, and considering the result of Test No11 and the processing accuracy such as dimensional tolerance together, It was determined that the ratio of the height of the convex portion and the concave portion to be “Ha / Hb <1.1” was optimal.

  Moreover, in the abrasion generation test, it was confirmed that abrasion occurred in Test No9. In this result, the ratio of the height of the convex part and the concave part to be paired is “Ha / Hb = 0.75”, and even if the convex part can be fitted into the concave part, the wear occurs when the gap is large. It was confirmed that. On the other hand, in Test No. 8, “Ha / Hb = 0.8”, and there was some gap, but no wear occurred. However, when “Ha / Hb = 0.8”, it is clear that there is a gap visually, but as a lower limit, the ratio of the height of the paired convex portion and concave portion is “0.8 <Ha / Hb”. It was judged that it was optimal.

  From the above experimental results, the dimension conditions of the convex portions and the concave portions facing each other in the width direction are “1 ≦ Ra / Rb <1.2” and “0.8 <Ha / Hb <1.1”. The relationship was determined to be optimal. Further, since the occurrence of wear was not confirmed for all the lower arms within the range, the convex portions and concave portions of the concave and convex portions 17 were formed at the abutting portions of the notched edge portions 16 and fit or fitted. Thus, the effect of improving rigidity and suppressing wear (durability) could be sufficiently confirmed.

  The first embodiment of the present invention has been described above. That is, in the lower arm 10 according to the present embodiment used as a suspension arm for automobiles, the contracted tube portion 14 is provided with slit-shaped notches 15 along the longitudinal direction from the end portion on the upper and lower surfaces of the rectangular tubular member. It is formed by pressing from both sides and plastically deforming so that both side surfaces in the width direction of the notch edge 16 are abutted so as to fill the gap formed by the notch 15. In other words, the contraction tube portion 14 is formed by being contracted so as to form a closed section by pressing the upper surface and the lower surface divided by the notch 15 from both sides.

  When the contraction tube portion 14 is formed in this way, the deformation point can be controlled at the central portion of the upper surface and the lower surface, the upper surface and the lower surface can be flat, and both side walls can be formed in a substantially parallel closed cross section without any deformation. And a certain dimensional accuracy required for attaching the bush 11 can be obtained. Here, in the approximate center of the lower arm 10, particularly in the vicinity of the coil spring support portion 13, the region and the cross-sectional area are secured with the original plate thickness, so that the rigidity against the force received from the coil spring 7 is also maintained. In addition, since it is formed from the square tubular extrusion material of aluminum alloy, it cannot be overemphasized that manufacture is easy and it meets a market demand with light weight.

  And in the lower arm 10 which concerns on this Embodiment, in the notch 15 of the lower arm 10 formed of the notch 15, the uneven | corrugated shaped part 17 which a some recessed part and convex part oppose in the width direction (short direction) is formed. However, when they are pressed from both sides and brought into contact with each other, they are tightly fitted or fitted into each other.

  The suspension arm receives a force in the torsional direction when the vehicle travels. However, if the notch edge 16 formed by the notch 15 is just abutted here, the notch edge 16 slides up and down. A sufficient strength against torsion cannot be ensured, and further wear may occur.

  On the other hand, in the lower arm 10 according to the present embodiment, the concavo-convex shape portion 17 formed in the notch 15 is tightly fitted or fitted, so that the lower arm 10 is firmly joined while being weldless. Therefore, the lower arm 10 according to the present embodiment is wearless and satisfies a desired dimensional condition and is lightweight, yet has a strong rigidity against torsion and can secure strength, and suppresses the vertical movement of the notched edge portion 16 to wear. It is also possible to prevent the occurrence of

  Further, in the lower arm 10 according to the present embodiment, insertion holes 18 are formed in both side walls of the contracted tube portion 14, and an outer cylinder 19 is expanded and caulked to be fixed thereto. As a result, both side surfaces of the notch edge portion 16 formed by the notch 15 are more firmly coupled, thereby further improving the rigidity against torsion and preventing the occurrence of wear reliably. it can.

  Moreover, about the lower arm 10 which concerns on this Embodiment, the optimal dimensional condition in the uneven | corrugated shaped part 17 was able to be found under sharp research. That is, as a dimensional condition of a pair of convex portions and concave portions facing each other in the width direction, the radius (Ra) of the convex portion, the radius (Rb) of the concave portion, the height (Ha) of the convex portion, and the depth (Hb) of the concave portion In this case, by forming the convex portions and the concave portions in the range of “1 ≦ Ra / Rb <1.2” and “0.8 <Ha / Hb <1.1”, the convex portions and the concave portions are more It was found that they can be firmly bonded and wear can be prevented.

  Further, in the lower arm 10 according to the present embodiment, the shape in which the convex portions and the concave portions in the concave and convex portion 17 are opposed to each other in four pairs in the vehicle width direction has been described. It is not limited. Since the convex portion is pressed into the concave portion and the vertical movement is suppressed, for example, there is one pair of the convex portion and the concave portion, and the effect of improving the strength and reducing the wear can be obtained. However, when three or more pairs are formed, the convex portions and the concave portions cause a tightening force in the longitudinal direction of the lower arm 10 to act on the adjacent convex portions and concave portions. Therefore, when three or more pairs of convex portions and concave portions are formed, the effect of improving the strength and reducing the wear can be obtained.

  Further, in the lower arm 10 according to the present embodiment, the contracted tube portion 14 is formed only on the connection side with the vehicle body structural member 5, but the knuckle 4 side may be similarly contracted depending on the design conditions. Further, in the lower arm 10 according to the present embodiment, the notch 15 is formed in the upper side rib 10A and the lower side rib 10B and the tube is contracted, but the notch is formed in the opposite side wall 10C and the side wall 10D. The tube may be contracted.

  Further, in the present embodiment, the concavo-convex shape portion 17 is formed on the opening side in the longitudinal direction of the notch 15 so as to be wavy, that is, arc-shaped convex portions and arc-shaped concave portions are arranged in a staggered manner, and The convex portion and the concave portion are formed to face each other in the width direction. However, since the concavo-convex shape portion 17 presses the convex portion into the concave portion to suppress the vertical movement, it may have a shape other than the wavy shape. That is, a trapezoidal shape or the like may be used as long as it can be firmly bonded to form a closed cross section when pressed.

  In the present embodiment, the structural member according to the present invention has been described as the lower arm 10 in the multilink suspension device, but the suspension device may be of a different method. That is, for example, even in the double wishbone method, the structural member according to the present invention can be suitably used as the lower arm. In the double wishbone system, the mode in which the lower arm supports the coil spring is a common one.

  In the present embodiment, the lower arm 10 is manufactured using an aluminum alloy. However, even if a magnesium alloy is used, the lower arm 10 is lightweight, is light while satisfying the desired dimensional condition, and satisfies the desired dimensional condition without welding. A lower arm with light weight and high rigidity can be obtained. In the present embodiment, the lower arm 10 used in the suspension device 1 has been described as a structural member according to the present invention, but the present invention is not limited to this and can be used in a wide range of fields. For example, as a rod-shaped member, if light weight is required and a narrow part is required, it is used in various vehicles, robots, buildings, and mechanical structures provided in buildings. The application field is wide.

<Second Embodiment>
Next, a second embodiment of the present invention will be described. FIG. 18 is a diagram showing the concave and convex portions of the lower arm according to the present embodiment in which the shapes of adjacent convex portions or concave portions are different.

  In the experiment described with reference to FIGS. 16 and 17 in FIG. 1, it has been found that if the convex portions and the concave portions facing in the width direction satisfy a predetermined dimensional condition, they are firmly bonded and wear does not occur. . From this result, the pair of opposed convex portions and concave portions are firmly bonded and no wear occurs if a predetermined dimensional condition is satisfied for each pair. Therefore, in the present embodiment, the pair of convex portions facing each other in a range satisfying “1 ≦ Ra / Rb <1.2” and “0.8 <Ha / Hb <1.1” as the dimensional condition. And the shape of the recess was made different for each pair. The parameters are the same as those in the first embodiment.

  DESCRIPTION OF SYMBOLS 1 Suspension apparatus, 2 tire, 3 wheel, 4 knuckle, 5 vehicle body structural member, 6 upper arm, 7 coil spring, 10 lower arm, 10A upper surface lateral rib, 10B lower surface lateral rib, 10C, 10D side wall, 11 bush, 12 insertion hole , 13 Coil spring support part, 14 Reduced tube part, 15 Notch, 16 Notch edge part, 17 Concave and convex part, 18 Insertion hole, 19 Outer cylinder, 20 Rubber material.

Claims (13)

At least at one end side in the longitudinal direction of the rectangular tubular member, a notch is formed along the longitudinal direction from the end portion on the upper surface and the lower surface or opposite side walls so as to fill a gap formed by the notch. It is a structural member that is contracted by being pressed,
In the notch, the upper and lower surfaces, or the concave and convex shapes facing each other in the lateral direction of the both side walls are formed, and the concave and convex shapes are formed by the notches in a state of being closely fitted or fitted to each other. A structural member, wherein the gap is filled.   The structural member according to claim 1, wherein the rectangular tubular member is an extruded material made of an aluminum alloy.   The structural member according to claim 1, wherein the structural member is a suspension arm in an automobile suspension device.   The said uneven | corrugated shape is a shape where two or more pairs of the convex part and recessed part which oppose in the transversal direction of the said upper surface and lower surface or the both side walls were located in a line. The structural member as described in.   The structural member according to claim 4, wherein a plurality of pairs of the convex portions and the concave portions facing each other are alternately arranged.   The structural member according to claim 5, wherein at least three pairs of the opposing convex portions and concave portions arranged in a row in a staggered manner are at least three pairs.   The said convex part and the said recessed part are circular arc shape, The structural member of any one of Claims 4-6 characterized by the above-mentioned. The notch is formed flat along the longitudinal direction on both sides except the portion where the uneven shape is formed, and when the convex portion and the concave portion are arc-shaped,
The height of the convex portion based on the flatly formed portion of the notch is defined as Ha, the depth Hb of the concave portion,
When the radius of the convex portion is Ra and the radius of the concave portion is Rb,
Between the opposed convex and concave pairs,
The structural member according to claim 7, wherein a relationship of 1 ≦ Ra / Rb <1.2 and 0.8 <Ha / Hb <1.1 is satisfied. The notch is not formed, the upper surface and the lower surface, or the insertion holes are formed in the both side walls, a connecting member is provided in the insertion hole,
9. The connection member according to claim 1, wherein the coupling member applies a tightening force toward the upper surface and the lower surface in which the notch is formed, or toward the center in the short direction of the both side walls. The structural member as described. The connecting member is a cylindrical member,
The structural member according to claim 9, wherein the cylindrical member is inserted into the insertion hole, and is fixed to the insertion hole by caulking at both ends thereof at least partially.   The structural member according to claim 10, further comprising a bush held inside the cylindrical member.   An automobile comprising the structural member according to any one of claims 1 to 11 as a suspension arm. When at least one end in the longitudinal direction of the rectangular tubular member is formed with notches in the upper and lower surfaces, or both side walls along the longitudinal direction from the end portions, the upper and lower surfaces, or Forming a concavo-convex shape opposed in the lateral direction of the side walls;
Pressing the square tubular member so that the gap formed by the notch is filled, and the uneven shape is tightly fitted or fitted to each other,
A method for producing a structural member, comprising: obtaining a structural member having at least one end that is contracted.

Images