U.S. patent application number 09/832911 was filed with the patent office on 2001-08-09 for method of manufacture of a structural body.
Invention is credited to Ezumi, Masakuni, Fukuyori, Kazusige, Satou, Akihiro.
Application Number | 20010011674 09/832911 |
Document ID | / |
Family ID | 27320061 |
Filed Date | 2001-08-09 |
United States Patent
Application |
20010011674 |
Kind Code |
A1 |
Ezumi, Masakuni ; et
al. |
August 9, 2001 |
Method of manufacture of a structural body
Abstract
The rotary tools are disposed to weld along two spaced welding
lines. The two rotary tools are inserted into respective welding
joints and moved at the same time along the respective welding
lines. At a position PI of a portion of a window one rotary tool is
withdrawn from the welding joint so that the friction stir welding
on that welding joint is stopped although the welding tool
continues to move. At a position P3, the rotary tools are gradually
withdrawn from their respective welding joints while they continue
to move along the welding line. At a position P4, the movement of
the rotary tools along the respective welding lines is stopped, the
rotary tools are completely withdrawn and the welding is stopped.
Next, the rotary tools are inserted into the respective welding
joints once again and movement thereof is started again. An
insertion amount of the rotary tools at this time is larger than
the insertion amount thereof prior to the stopping of the movement
of these rotary tools.
Inventors: |
Ezumi, Masakuni;
(Kudamatsu-shi, JP) ; Fukuyori, Kazusige;
(Kudamatsu-shi, JP) ; Satou, Akihiro;
(Hitachi-shi, JP) |
Correspondence
Address: |
ANTONELLI TERRY STOUT AND KRAUS
SUITE 1800
1300 NORTH SEVENTEENTH STREET
ARLINGTON
VA
22209
|
Family ID: |
27320061 |
Appl. No.: |
09/832911 |
Filed: |
April 12, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
09832911 |
Apr 12, 2001 |
|
|
|
09572985 |
May 17, 2000 |
|
|
|
Current U.S.
Class: |
228/112.1 ;
228/2.1 |
Current CPC
Class: |
Y02T 30/00 20130101;
B23K 2101/26 20180801; B23K 2101/045 20180801; B61D 17/04 20130101;
B23K 33/00 20130101; B23K 20/122 20130101 |
Class at
Publication: |
228/112.1 ;
228/2.1 |
International
Class: |
B23K 020/12; B23K
037/00; B23K 031/02 |
Foreign Application Data
Date |
Code |
Application Number |
May 31, 1999 |
JP |
11-151129 |
May 31, 1999 |
JP |
11-151130 |
May 31, 1999 |
JP |
11-151131 |
Claims
What is claimed is:
1. A method of manufacturing a structural body, comprising the
steps of: starting friction stir welding by inserting respective
rotary tools into respective welding joints of members to be
welded; at a first position, withdrawing one of said rotary tools
from its welding joint, while continuing movement of said one of
rotary tools and others of said rotary tools along their respective
welding joints; at a second position, inserting said one of said
rotary tools into its welding joint.
2. A method of manufacturing a structural body wherein friction
stir welding is performed to join a plurality of members using
respective rotary tools inserted in respective welding joints and
moving said respective rotary tools along said respective welding
joints between said members to be subjected to welding, said method
comprising the steps of: at a first position which is midway of
said movement of said respective rotary tools, starting a
withdrawal of one of said rotary tools to separate it from said
members to be subjected to welding; at a second position which is
midway of said movement of said respective rotary tools and which
is located downstream of an intermittent welding portion of said
welding joint of said one of said rotary tools, starting an
insertion of said one of said rotary tools into the welding joint
of said members to be subjected to the welding while carrying out
said movement and a rotation of said one of said rotary tools along
its welding joint; and holding substantially an insertion depth
while inserting said one of said rotary tools to a predetermined
position.
3. A manufacturing method according to claim 2, wherein said first
position and said second position are located on projecting members
which, after the friction stir welding is finished, are cut off and
removed.
Description
[0001] This is a divisional application of U.S. Ser. No.
09/572,985, filed May 17, 2000.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a method of manufacturing a
structural body using a friction stir welding method; and, for
example, the invention relates to a manufacturing method suitable
for the manufacture of a car body of a railway vehicle
[0003] Friction stir welding is a method wherein a round rod
(called a "rotary tool"), which is inserted into a welding joint,
is rotated and moved along the welding joint so that the welding
joint is heated, softened and solid-fluidized, whereby a solid
phase welding occurs.
[0004] The rotary tool comprises a small diameter portion which is
inserted into the welding joint, and a large diameter portion which
is positioned outside of the small diameter portion. The small
diameter portion and the large diameter portion of the rotary tool
have the same axis of rotation. A boundary between the small
diameter portion and the large diameter portion of the rotary tool
is inserted slightly into the welding joint. The rotary tool is
inclined toward the rear relative to the advancing direction of the
welding.
[0005] A car body of a railway vehicle is constituted by carrying
out a friction stir welding of plural extruded frame members. The
longitudinal direction of the extruded frame member is directed in
the longitudinal direction of the car body, and the width of the
extruded frame member is arranged in the direction of the height of
the car body. To a side face of the car body with the above-stated
construction, an opening, such as a door or window, is typically
provided by cutting-out a portion of the extruded members.
[0006] The above-stated technique is disclosed in Japanese
application patent laid-open publication No. 09-309164 (EP
0797043A2).
[0007] Since the height of a window of a car body is typically
larger than the width of an extruded frame member, the window is
formed by an opening cut into two or three frame members. For this
reason, the extruded frame members in which a cut-off portion is
provided are substantially aligned to form the window and then
joined by welding. A friction stir welding apparatus for
manufacturing a car body comprises a bed for mounting plural
extruded frame members and a gantry disposed over the bed and from
which plural rotary tools are suspended. By controlled movement of
the gantry, the plural rotary tools are moved so that plural
extruded frame members can be welded simultaneously.
[0008] In a case where the plural extruded frame members are welded
simultaneously using plural rotary tools which are suspended from a
gantry, when a first rotary tool reaches a position where a window
is located, this rotary tool is withdrawn from the extruded frame
member, and the friction stir welding being performed by this
rotary tool is stopped. Meanwhile, a second rotary tool for welding
a portion where a window does not exist is allowed to continue the
friction stir welding as it is. When the first rotary tool is moved
to a position at the other end of the window, this first rotary
tool is inserted once again into the weld joint and the friction
stir welding is resumed.
[0009] When this process is carried out, by removing the first
rotary tool from the welding joint at one side of the window and
then re-inserting into the welding joint at the other side of the
window, a defect in the welding can be generated easily. Further,
at an initial time during the start of the friction stir welding
since the temperature of the welding joint has not yet been raised,
a large insertion force is required for inserting the rotary tool
into the welding joint.
[0010] In addition to the above, since the rotary tool is moved
while it is inserted into the welding joint, a slant force is
generated against a bearing member of the rotary tool. For this
reason, the bearing member is required to be large in size, and a
problem with the life expectancy of the rotary tool occurs. Summary
of the Invention
[0011] A first object of the present invention is to obtain good
friction stir welding in a case of welding plural lines
simultaneously, while a portion of the member or members to be
subjected to welding does not exist or in which friction stir
welding is unnecessary, when the friction stir welding begins again
after being interrupted.
[0012] A second object of the present invention is to perform
friction stir welding in a short time in a case of welding plural
lines simultaneously, where a portion of the member or members to
be subjected to welding does not exist or in which friction stir
welding is unnecessary.
[0013] The above-stated first object can be attained by a method of
manufacturing a structural body comprising the steps of: starting a
friction stir welding by inserting respective rotary tools into
plural welding joints at a first position; stopping the friction
stir welding of one welded joint by withdrawing one of the rotary
tools from that welding joint, while continuing movement of the one
of the rotary tools accompanying movement of the other of the
rotary tools at a second position; stopping the movement of the
respective rotary tools and stopping the friction stir welding
while withdrawing the other of the rotary tools from its welding
joint; inserting the respective rotary tools to a predetermined
depth into each respective welding joint; and starting the friction
stir welding by again starting the movement of the respective
rotary tools along their respective welding joints.
[0014] The above-stated second object can be attained by a method
of manufacturing a structural body comprising the steps of:
starting friction stir welding by inserting respective rotary tools
into plural welding joints at a first position; withdrawing one of
the rotary tools from a welding joint, while continuing movement
thereof accompanying movement of others of the rotary tools at a
second position; and then inserting the one of the rotary tools
into its welding joint once again.
BRIEF DESCRIPTION OF DRAWINGS
[0015] FIG. 1 is a diagram showing a method of manufacture of a
structural body representing one embodiment according to the
present invention;
[0016] FIG. 2 is a flowchart showing a method of manufacturing a
structural body according to the present invention;
[0017] FIG. 3 is a longitudinal cross-sectional view showing a
structural body according to the present invention;
[0018] FIG. 4 is a perspective view showing a friction stir welding
apparatus for manufacturing a structural body according to the
present invention;
[0019] FIG. 5 is a perspective view showing a car body of a railway
vehicle according to the present invention; and
[0020] FIG. 6 is a diagram showing a method of manufacture of a
structural body representing another embodiment according to the
present invention.
DESCRIPTION OF THE INVENTION
[0021] One embodiment of a method of manufacture of a structural
body according to the present invention will be explained with
reference to FIG. 1 to FIG. 5. As a structural body, a railway car
body will be referred to by way of example. As shown in FIG. 5, the
car body comprises a side structure 201 for constituting a side
face of the car, a roof structure 202 for constituting a roof of
the car, a bogie frame 203 for constituting a floor of the car, and
an end structure 204 for constituting an end of the car body.
[0022] The side structure 201, the roof structure 202, and the
bogie frame 203 are constituted respectively by joining plural
extruded frame members. The longitudinal direction of each of the
extruded frame member is directed in the longitudinal direction of
the car body. The material of the extruded frame member is an
aluminum alloy.
[0023] As shown in FIG. 5, the side structure 201 comprises
extruded frame members 10, 20, 30 and 40. In the extruded frame
members 20 and 30, a window opening 210 is provided by cutting away
parts of the frame members 20, 30. An inlet and outlet port
(doorway) 220 of the side structure 201 is provided by cutting away
parts of the extruded frame members 10, 20, 30 and 40. As to the
inlet and outlet port 220, after the extruded frame members 10, 20,
30 and 40 have been joined, in many cases a frame is welded in
position. The window 210 is formed in a similar way. The extruded
frame members 10, 20 and 30 of the inlet and outlet port 220 are
cut off at a respective midway portion.
[0024] This side structure 201 is comprised of the four extruded
frame members 10, 20, 30 and 40, however, in a case of a hollow
extruded frame member, the side structure 201 may be constituted by
many more extruded frame members. Further, it is possible for the
window 210 to be constituted by three extruded frame members. In
this case, a central extruded frame member is cut off at a midway
portion.
[0025] The construction of the extruded frame members used to form
the side structure 201 will be explained with reference to FIG. 3.
Herein, the joining of the extruded frame members 20 and 30 will be
explained. The other frame members 10 and 40 are similar in
configuration to these extruded frame members 20 and 30. The
extruded frame members 20 and 30 are hollow frame members.
[0026] The hollow frame member 20 comprises two face plates 21 and
22, plural ribs 23 arranged in a truss shape for connecting the
face plates 21 and 22, and a supporting plate 24 for connecting the
two face plates 21 and 22 in an end portion (a joining portion) in
a width direction of the hollow frame member 20. The hollow frame
member 30 comprises two face plate 31 and 32, plural ribs 33
arranged in a truss shape for connecting the face plates 31 and 32,
and a supporting plate 34 for connecting the two face plates 31 and
32 in an end portion (a joining portion) in a width direction of
the hollow frame member 30.
[0027] In the width direction of the end portion (the joining
portion) of the face plates 21 and 22, a raised portion 25
projecting toward the outside of the respective face plate is
provided. In the width direction of the end portion (the joining
portion) of the face plates 31 and 32, a raised portion 35
projecting toward then outside of the respective face plate is
provided. At the end portion in the width direction of the hollow
frame member 30, a pair of projection chips 36 projecting toward
the opposite hollow end of the frame member 20 are provided. The
projection chips 36 are located between the face plates 21 and 22
at the end portion of the face plates 21 and 22 of the hollow frame
member 20 so as to form a seat for supporting the insertion force
of a rotary tool 340.
[0028] The width of the two raised portion 25 are the same, and an
end face of the raised portion 35 which bears against the raised
portion 25 is arranged to extend substantially along the center of
the plate thickness of the supporting plate 34. At a center of the
surface formed by the two raised portions 25 and 35, i.e., where
the welding joint is located, the rotation axial center of the
rotary tool 340 of the friction stir joining apparatus 330 is
positioned.
[0029] As seen in FIG. 4, the extruded frame members 10, 20, 30 and
40 constituting the side structure 201 are mounted on a bed 310 of
the friction stir welding equipment 300 and are fixed to the bed
310 by suitable means. Above the plural extruded frame members 10,
20, 30 and 40 a gantry 320 runs on rails 329 located on both sides
of the bed 310. From a girder 321 of the gantry 320, three friction
stir welding apparatuses 330 are suspended.
[0030] The friction stir welding apparatuses 330 operate to raise
and lower the rotary tools 340 for welding the frame members
positioned on the bed 310. The respective friction stir welding
apparatuses 330 can be independently moved along the girder 321 to
a welding position, at which the rotary tools 340 can be
independently raised and lowered while rotating to effect selective
welding.
[0031] The respective friction stir welding apparatuses 330 are
provided with an optical sensor which detects the distance from the
apexes of the raised portions 25 and 35 and sets an insertion
amount of the rotary tool 340 at a predetermined value. Further,
the optical sensors detect width of the surface formed by the
raised portions 25 and 35 and determines a center thereof to
position the axial center of the rotary tool 340 for welding.
[0032] In the extruded frame members 20 and 30 on which a window
210 is provided, an opening (a cut-off portion) having
substantially a window shape is provided at the position of the
window in advance. This opening is provided by cutting out a
portion of the extruded frame members 20 and 30. Similarly, the
extruded frame members 10,20 and 30 in which the inlet and outlet
port 220 is provided are cut off and are arranged to accommodate
the interval of the inlet and outlet port 220. In the extruded
frame member 40 for constituting an upper end of the inlet and
outlet port 220, an opening (a cut-off portion) having a
substantially inlet and outlet port shape is provided at a position
of the inlet and outlet port 220 in advance. This opening is
provided by cutting out a portion of the extruded frame member
40.
[0033] The formation of the window 210 will be explained. The
welding joint of the extruded frame members 20 and 30 has a welding
line having a start end and a finish end in the window 210. For
this reason, as seen in FIG. 1, the extruded frame members 20 and
30 in a vicinity of the welding line are cut off while leaving the
extending portions 28, 38 and 29, 39 which project into the window
210. The width of the respective extending portions 28, 38 and 29,
39 is set to have the same dimension as the supporting plates 24
and 34 and the raised portions 25 and 35. The formation of the
inlet and outlet port 220 is carried out similarly. The extruded
frame members 10, 20, 30 and 40 are cut off while leaving
respective extending portions 28, 38 and 29, 39. Further, the
extending members chips 28, 38 and 29, 39 are provided respectively
on both ends in the longitudinal 10 direction of the side structure
201.
[0034] The hollow frame members 10,20, 30 and 40 are mounted on and
fixed to the bed 310 using a fixing means. When the hollow frame
members 10, 20, 30 and 40 have been fixed, the raised portions 25
and 35 of the abutting portions of the hollow frame members 10,20,
30 and 40 are fixed intermittently and temporarily along the
welding lines by arc welding. The extreme ends of the extending
portions 28, 38,29 and 39 at the start end and the finish end of
the welding line are also fixed temporarily.
[0035] A reference "W" in FIG. 1 shows where the temporary welding
occurs. In particular, the temporary welding W of the start end is
carried out on upper faces of the raised portions 25 and 35 and on
a face of the extreme end portion in the longitudinal direction of
the hollow frame members 10, 20, 30, and 40. The range of the
temporary welding "W", on the face of the extreme end portion is
from the upper faces of the raised portions 25 and 35 to the
projection chip 36. The temporary welding "W" does not provide a
V-shaped groove, but provides an I-shaped groove.
[0036] In this condition, from one end in the longitudinal
direction of the hollow frame member, the friction stir welding is
started. To the raised portions 25 and 35 of these chips at the
starting end of the welding line, by rotating the respective rotary
tools 340, a rotary tool 340 is selectively lowered and inserted
into the welding joint. The insertion position is located at the
finish end of the welding line on the other side of the temporary
welding W location at the end portion of the chip. For example, the
insertion position is a position P4 of the rotary tool 340A as
shown in FIG. 1.
[0037] The chip end of the small diameter portion 341 of the rotary
tool 340 is inserted into an upper face of the surface formed by
raised portions 25, 35 to the depth of the projection chip 36. The
position to which the lowest end of the large diameter portion 342
of the rotary tool 340 is inserted is between the plane of the
outer faces of the face plates 21 and 31 (the face plates 22 and
32) and an apex of the raised portions 25 and 35. The position of
the axial center of the rotary tool 340 is midway between the sides
of the two raised portions 25 and 35. The axial centers of the
small diameter portion 341 and the large diameter portion 342 of
the rotary tool 340 are the same. The small diameter portion 341 of
the rotary tool 340 is in the form of a screw member.
[0038] When the respective rotary tools 340 are inserted to a
predetermined depth into the surface of the respective
hollow-extruded members, the movement of the gantry 320, which
carries plural friction stir welding apparatuses 330, is started to
carry the welding apparatuses toward the other end, so that
friction stir welding is carried out.
[0039] Next, the operation of the friction stir welding apparatus
330 in the vicinity of the window 210 and the inlet and outlet port
220 will be explained with reference to FIG. 1 and FIG. 2. Herein,
the formation of the window 210 will be considered by way of
example. The rotary tool 340 which operates on the welding line
intercepted by the window 210 is indicated as "340A" and the rotary
tools 340 which operate on the welding lines not intercepted by the
window 210 are indicated as "340B". The rotary tools 340A and 340B
are inserted at the same time and move from left to the right as
shown in FIG. 1.
[0040] When the friction stir welding has advanced from the end
portion of the extruded frame member to a point where the rotary
tools 340A and 340B reach the position P1 of the extending portions
28 and 38 at the window 210, while continuing the rotation of the
rotary tool 340A, the rotary tool 340A is withdrawn from the
welding joint. Namely, the rotary tool 340A is raised, but the
forward movement is continued. For this purpose, the rotary tool
340A is raised gradually. The position PI is determined by the
running distance (position) of the gantry 320. The position PI is
determined in advance. (step S10 and step S30).
[0041] After the friction stir welding is completed, the extending
portions 28 and 38 will be cut off in line with the edge of the
window opening. For this reason, since the extending portions 28
and 38 are positioned at an upstream side of the position P1, there
is no problem about the welding depth from the strength aspect of
the remaining welded portion. The rotary tools 340B are not raised
at the position P1 since the window 210 does not interrupt the
welding lines associated therewith. The rotary tools 340B continue
to move along their respective welding lines and the friction stir
welding performed thereby is continued beyond the position P1.
[0042] As stated above, since the rotary tool 340A is raised while
the forward movement thereof continues, without stopping the
welding being carried out by the rotary tools 340A and 340B, the
welding time can be shortened.
[0043] When the rotary tool 340A reaches the predetermined position
(a position P2), the raising of the rotary tool 340A and the
rotation thereof are stopped. At this point, the rotary tool 340A
has been elevated sufficiently that it is carried at a level about
the surface of the raised portions 25 and 35. When the small
diameter 341 of the rotary tool 340A has been pulled entirely out
(withdrawn) of the raised portions 25 and 35, the friction stir
welding is stopped along the welding line.
[0044] When the rotary tools 340A and 340B reach the other end of
the window 210, namely to a predetermined position P3, which is
this side of the extending portions 29 and 39, a raising
(withdrawal) of the rotary tools 340B starts. The speed of
withdrawal of the rotary tools 340B from the respective welding
joint is slow, while the movement of the gantry 320 continues. For
this reason, the welding depth at which the rotary tools 340B
operate become gradually more shallow. (step S50 and step S70).
[0045] When the rotary tool 340A reaches the position P4 at the
extending portions 29 and 39, the movement of the gantry 320 is
stopped. At this time, since the raising of the rotary tools 340B
is continued, these rotary tools 340B are pulled completely out of
the respective welding joints. At the position P4, the speed of
withdrawal of the rotary tools 340B may be increased. The position
P4 is located on the other side of the temporary welding position
W. (step 90 and step 110).
[0046] The distance between the position P3 and the position P4 is,
for example, 50 mm. The amount that the rotary tool 340B is
withdrawn between the position P3 and the position P4 is, for
example, 0.5 mm. With this amount of withdrawal, the welding depth
becomes small in the remainder of the extending portions 28, 38.
With this minimum welding depth, no problem occurs from the aspect
of the strength of the welded portion.
[0047] When the rotary tool 340B is pulled out, in the welded
portion a hole which corresponds to the diameter of the small
diameter portion 341 of the rotary tool 340 is formed.
[0048] Next, at the position P4, all rotary tools 340A and 340B are
made to rotate and descend, and the rotary tool 340A and the rotary
tools 340B are inserted into the welding joints to a predetermined
depth. The insertion amounts of the rotary tools 340A and 340B are
the regular (stationary) depth. (step S130).
[0049] The rotary tools 340B are inserted into the above-stated
holes. Since the insertion amount of the rotary tool 340B is the
regular depth, the insertion depth is the same as it was before the
position P3 (the insertion depth before the starting of the raising
of the rotary tool 340B). Namely, at the position P4, the depth is
the same as it was before the friction stir welding was stopped and
plus 0.5 mm. With this, from the lowest end portion of the
above-stated hole which was generated just before the rotary tool
340B was pulled out, the rotary tool is inserted deeply with an
additional 0.5 mm.
[0050] In this condition, the movement of the gantry 320 begins to
start. Using the rotary tools 340A and 340B, the friction stir
welding is started again. In this way, friction stir welding to the
regular depth is carried out (step S 150).
[0051] As stated above, in the position P4, by inserting the rotary
tools 340B into the holes which are formed prior to the pulling out
of the rotary tools 340B, the friction stir welding is carried out.
For this reason, the hole is buried with metal derived from the
raised portions 25 and 35 as the welding proceeds. Further, since
the position of the lower end of the rotary tool 340B is lower than
the lowest end of the above-stated hole, and since the lower
portion of the above-stated hole is joined fully, the occurrence of
a defect at this portion can be restrained. In particular, since by
the rotary tool 340B the lower portion at the bottom of the
above-stated hole is stirred fully, a defect at the center portion
of the bottom of the above stated hole can be avoided.
[0052] Further, even if a defect occurs at the central portion of
the bottom of the above-stated hole, the size of the defect will
not be large, and from the aspect of the strength of the weld, a
full joining can be obtained.
[0053] Since the insertion position of the rotary tool 240A is
located at the other side of the temporary welding position W of
the end of the extending portions 29 and 39, the gap between the
extending portions 29 and 39, which forms the welding joint, is not
enlarged. Accordingly, a good welding can be carried out.
[0054] The next window 210 is carried out in a similar way. Also,
the raising and lowering of the rotary tool 340 at the inlet and
outlet port 220 is carried out in a similar way. Further, it is not
necessary for all rotary tools 340 to be arranged on the same
line.
[0055] As stated above, the welding is carried out to the other
end, and then the structural body comprised of the plural hollow
frame members is turned over on the bed 310 and the friction stir
welding is carried out in a similar way. The raised portions at the
outer face side of the car body are cut off and the outer face
thereof is made to have the same smooth face as that of the face
plate.
[0056] Further, the following processing will be carried out. In a
case where a defect is not prevented with the above-stated
insertion depth at the position P4, the rotary tool 340 is inserted
even more deeply at this position and the welding portion is made
thick. As a result, after the start of movement of the rotary
tools, at the position P5 (or after a predetermined time lapses),
it is possible to carry out the raising of the rotary tool 340B.
Accordingly, the insertion depth becomes regular.
[0057] This ascent of the rotary tool 340B is carried out by a
height position control function of the rotary tool 340. The height
position control function of the rotary tool 340 is a function in
which the height of the raised portions 25 and 35 is detected by
the sensor, and the insertion amount from the raised portions 25
and 35 is given a predetermined value. With this, all rotary tools
340A and 340B are made to operate in a regular condition.
[0058] Further, the following processing will be carried out. Up to
the position P4 the friction stir welding is carried out with the
regular insertion depth, and at the position P4, the rotary tool
340B is pulled out. Next, at the position P4, the rotary tools 340A
and 340B are inserted once again into the respective welding
joints. The insertion depth of the rotary tool 340A is the regular
amount. The insertion amount of the rotary tool 340B is larger than
that of the regular amount; for example, it is plus 0.5 mm. At this
time, the movement (the running) of the rotary tools 340A and 340B
will start. After the of start movement, at the position P5 (or
after the predetermined times lapses), the raising of the rotary
tool 340B starts. The of speed withdrawal of the rotary tool 340B
is slow, while the movement of the gantry 320 continues. For this
reason, the welding depth of the rotary tool 340B becomes gradually
more shallow.
[0059] When the rotary tool 340B is withdrawn to the predetermined
position (the insertion depth before the position P4), the
withdrawal of the rotary tool 340B is stopped. Accordingly, all
rotary tools 340A and 340B are in a regular condition. Further, the
positions P1, P2, P3 and P4 can be managed according to the
time.
[0060] At the position where the rotary tool 340B are pulled out
and then the rotary tools 340 can not be inserted immediately for
some reason, after movement of the gantry 320 is started, at the
position P4, the rotary tools 340A and 340B can be inserted into
the respective welding joints.
[0061] Further, at the position P4 where the rotary tools 340B are
pulled out, rather than insert the rotary tools 340B into the hole
which is formed by pulling the rotary tool 340B out, it is possible
to insert the rotary tool 340B at a position upstream of the
position P4. In this case, the insertion amount during the second
insertion of the rotary tool 340A will be the same as the insertion
amount during the case in which the former welding is carried
out.
[0062] Now, another embodiment of a method of manufacture of a
structural body according to the present invention will be
explained with reference to FIG. 6. When the rotary tool 340A and
the rotary tool 340B reach the other end of the window 210, namely
the rotary tools 340A and 340B reach the extending portions 29 and
39, the rotary tool 340A is lowered while it is rotating and then
the rotary tool 340A is inserted into the welding joint to a
predetermined depth. The insertion position P4, where the rotary
tool 340A is inserted into the extending portions 29 and 39 is on
the other side (a downstream side) of the temporary welding
position W.
[0063] Since the rotary tool 340A is lowered while it is moved
along the welding line, the welding depth becomes deep gradually.
When the insertion amount of the rotary tool 340A reaches a
predetermined amount, the lowering of the rotary tool 340A is
stopped (at position P5). Accordingly, friction stir welding at a
regular depth is carried out.
[0064] The position P5 where the insertion amount of the rotary
tool 340A becomes regular is on the extending portions 29 and 39
before reaching the edge of the window opening. After the welding
is complete, the extending portions 29 and 39 are cut off. The
insertion amount of the rotary tool 340A is controlled according to
the output of an optical sensor.
[0065] As stated above, since the rotary tool 340A is lowered while
moving the rotary tool 340A along the welding line, without
stopping the movement of either the rotary tool 340A or the rotary
tools 340B, to cause the rotary tool 340A to be inserted into the
welding joint between the hollow frame members 20 and 30, the time
for welding can be shortened.
[0066] Since the insertion position of the rotary tool 340A is
located on the other side of the temporary welding position W on
the extending portions 29 and 39, and welding commences prior to
the cut-off of the temporary welding portion, the gap between the
extending portions 29 and 39, which forms the welding joint, is not
enlarged. For this reason, a good welding can be carried out.
[0067] The gap between the two members at the insertion position
(the beginning end of the welding line) of the rotary tool 340 may
enlarge easily, however not only are the upper faces of the raised
portions 25 and 35 temporarily welded, but also temporary welding
is carried out on the end formed by the extending portions 29 and
39 in a thickness direction. Accordingly, the extruding portions 29
and 39 at the extreme end can be held together strongly. Thus, the
enlargement of the beginning end of the welding line can be
prevented easily.
[0068] Further, at the end portions of the hollow frame members 20
and 30, namely at the first insertion position of the rotary tools
340A and 340B, the extending portions 29 and 39 are provided, and
the temporary welding portion W and the insertion position of the
rotary tools 340A and 340B are formed in a manner similar to that
of the former embodiment. Accordingly, in comparison with the case
of temporarily welding only the upper face of the hollow frame
members, the length of the chip can be shortened. Accordingly, the
length of the hollow frame member can be shortened.
[0069] The technical range according to the present invention is
not limited to the description of each embodiment defined in the
claims items and the wordings of the description of the items for
solving the problem and it can refer to the range in which the
ordinary man belonged to this technical field can replace
easily.
[0070] According to a first feature of the present invention, in
the case where the welding of plural lines is to be carried out at
the same time using friction stir welding, and where there is a
portion along the welding line where the members to be subjected to
the welding not exist and where friction stir welding is
unnecessary, when the interrupted welding is started again, a good
friction stir welding can be obtained.
[0071] According to the second feature of the present invention, in
the case where the welding of plural lines is to be carried out at
the same time using friction stir welding, and where a portion
exists along the welding line where the members to be subjected to
welding do not exist and in which friction stir welding is
unnecessary, when the interrupted welding is started again, the
welding can be carried out in a short time.
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