Friction stir processing device and welding, material adding and energy control method

Abstract

The invention provides a stirring friction machining device and a welding, material adding and energy control method. The stirring friction machining device comprises a spinning sleeve and a rotation driving assembly, a rotating spinning screw is installed in the spinning sleeve, the rotation driving assembly drives the spinning screw to rotate through a cutter handle, and a stirring component is arranged at the bottom end of the spinning screw; the outer side of the spinning sleeve is coated with an electromagnetic resistance composite coil with adjustable current and frequency, a feeding port and / or a shredding port are / is formed in the side wall of the spinning sleeve, and variable magnetic field intensity is excited through the electromagnetic resistance composite coil according to the electromagnetic induction principle; according to the invention, accurate adjustment of heat input of a tool is realized by adjusting current in a staying starting stage, the problem that a feeding channel is blocked by hardening of materials after short staying during material adding or welding is solved, and composite stirring of metal in a deposition edge area is realized by adjusting the magnitude and frequency of the current as a dominant electromagnetic force. And meanwhile, the temperature distribution characteristics of the acting area are locally adjusted, the interface bonding strength is improved, and the residual stress of the additive component is relieved.

Description

Technical Field

[0001] The present invention relates to the technical field of solid-phase welding and solid-phase additive manufacturing, and in particular to a friction stir processing device and a welding, additive manufacturing and energy control method. Background Art

[0002] In the field of metal additive manufacturing, the feeding mechanism is the core component for achieving layer-by-layer material accumulation. This type of mechanism plasticizes the material through mechanical extrusion and friction to deposit the material into the processing area.

[0003] Chinese patent CN114799480A proposes a method and apparatus for non-stop wire feeding of solid-state friction stir additive manufacturing. This involves synchronously and non-stop feeding of filamentary additive material through a wire feed channel into the space between the internal storage chamber of the wire feed device and the crushing blades of the friction stir device. The material is then crushed into granules by the threads of the friction stir device. The additive material then moves downward along the screw and accumulates heat, ultimately achieving solid-state friction stir additive manufacturing. However, the integrated cutting tool blade is susceptible to wear, and the entire tool must be replaced for different materials, making it impossible to flexibly add multiple materials.

[0004] Therefore, Chinese patent CN113118612B proposes a granular friction stir additive manufacturing device and method, in which the cutting part is separated from the friction stir welding electric spindle, and the wire material to which it belongs is cut into granules and fed into the electric spindle to realize solid phase additive manufacturing. However, in the above method, during the wire feeding and stirring additive manufacturing process, the frictional heat generated by the tool and the metal material and the heat conduction in the processing area will cause the temperature of the feeding mechanism (such as the feeding channel, the stirring component, etc.) to rise. When the wire material is heated up, the material softens, and the material that is not extruded in time adheres to the inside of the tool (including the feeding port). In particular, when the mechanism is temporarily stopped due to process adjustment, equipment suspension, etc., the material that was previously in contact cools and hardens, and will form a strong adhesion with the feeding mechanism and hinder the next feeding, resulting in the problem of being unable to feed continuously and the increase of the motor starting torque when restarting, which seriously affects the processing efficiency and service life of additive manufacturing.

[0005] To address the problem of material sticking and clogging, conventional technology often uses a Chinese patent, a friction stir additive manufacturing tool cleaning device and method (CN116988134 B). However, this method has significant drawbacks: Firstly, electrochemical corrosion takes a long time to completely remove the sticking material, and the byproducts formed by corrosion affect the quality of the additive build and require further cleaning, resulting in increased equipment downtime and reduced production efficiency. Secondly, the corrosion process has strict restrictions on the type of materials. For some special metals or composite materials, electrochemical corrosion may not be effective and may even damage the feed mechanism itself.

[0006] Therefore, the Chinese patented friction stir wire feeding additive manufacturing device and friction stir wire feeding additive manufacturing method CN118321706A uses an auxiliary coil to heat the sleeve. A large amount of heat input causes the wire in the wire feeding hole to soften and adhere to the wire feeding port. Water cooling is used, and the inevitable contact between water and the coil can easily lead to short circuit safety hazards. The large heating and cooling system affects the flexibility of the additive structure.

[0007] In addition, at the edge of the additive deposition area, in order to meet sufficient extrusion, extruded material will be deposited outside the stirring area, but this area does not experience stirring, and there is an oxide interface between the deposited layers, which seriously affects the strength of the additive part. Conventional methods remove it through milling, reducing processing efficiency and reducing build quality.

[0008] In response to the above problems, there is an urgent need for a new stir friction processing device and method that can regulate the heat input of the processing area in real time, effectively solve the problem of intermittent continuous feeding, reduce the motor load and improve the interface bonding strength. Summary of the Invention

[0009] The purpose of the present invention is to provide a stir friction processing device and a welding, additive and energy control method to solve the problems of existing wire feeding stirring additive mechanisms such as material adhesion caused by material plasticization, feeding blockage caused by material hardening, difficulty in continuous feeding, excessive motor load and insufficient interface bonding strength.

[0010] Based on the above-mentioned purpose, the present invention provides a stir friction processing device, including a spinning sleeve and a rotary drive assembly, a spinning screw is rotatably installed in the spinning sleeve, the top end of the spinning screw is fixedly connected to the output end of the rotary drive assembly through a tool handle, and a stirring component is fixedly provided at the bottom end of the spinning screw; the outer side of the spinning sleeve is covered with an electromagnetic resistance composite coil, and a feeding port and / or a wire cutting port is opened on the side wall of the spinning sleeve.

[0011] Furthermore, it also includes a stationary shell, the spinning sleeve is fixedly installed at the bottom end of the stationary shell, the rotation drive assembly includes a rotating spindle and a first drive motor for driving the rotating spindle to rotate, the first drive motor is connected to a first motor power detector, and the displacement drive mechanism for driving the rotation drive assembly to move is connected to multiple second motor power detectors, each of the second motor power detectors corresponds to an execution motor, the stationary shell is covered on the outside of the rotating spindle, and the tool handle is installed at the bottom end of the rotating spindle.

[0012] Furthermore, the feed port is connected to the hopper of the wire chopper feeding mechanism, and the wire chopper feeding mechanism includes a hopper, a cutter disc, a medium conveyor and a wire feeder. The cutter disc is rotatably installed inside the hopper, and a wire chopper motor for driving the cutter disc to rotate is fixedly installed outside the hopper; the hopper is provided with a plurality of feed ports arranged in a circular array on the side away from the wire chopper motor, and each feed port is provided with a wire guide sleeve, and the wire feeder conveys the wire material to the cutter disc through the wire guide sleeve and cuts it into granules; the medium is conveyed and connected to the hopper through a guide pipe.

[0013] Furthermore, a heat insulation ring is provided inside or outside the electromagnetic resistance composite coil.

[0014] Furthermore, the stirring component is a welded non-thinning stirring structure, which includes a central stirring needle located at the center of the bottom of the spinning screw and an inclined groove or shoulder located at the edge of the bottom of the spinning screw, and the shoulder is a flat or concave structure.

[0015] Furthermore, the stirring component is an additive stirring structure, which includes a central stirring pin located at the center of the bottom of the spinning screw and an edge stirring pin located at the edge of the bottom of the spinning screw and arranged in a circular array. The length of the edge stirring pin is greater than the thickness of a single additive pass, the length of the central stirring pin is greater than the length of the edge stirring pin, and the width of the central pin and the edge pin is at least 1 / 15 of the diameter of the shaft shoulder.

[0016] Furthermore, the medium conveyor is an air pump, and the particles formed after the wire is cut are transported from the guide tube to the inside of the spinning sleeve by the gravity potential energy and the airflow provided by the air pump.

[0017] Furthermore, the bottom end of the silo is an inclined hopper, and the bottom end of the hopper is connected to the feed port through a material guide pipe.

[0018] Furthermore, multiple layers of tool holders are fixedly installed on the tool handle at the position of the wire cutting mouth of the spinning sleeve, and multiple blades are installed on each layer of the tool holder at equal intervals along its circumference. The installation stations for installing the blades on the two adjacent layers of the tool holders are staggered along the circumferential direction, and the types of blades installed on different layers of tool holders vary according to the different wire materials fed in.

[0019] Furthermore, a medium inlet is provided on the stationary housing, and the medium inlet is connected to the medium conveyor through a flow guide pipe.

[0020] A non-thinning welding method is implemented based on a friction stir processing device and comprises the following steps:

[0021] S1: Preheating stage: Turn on the AC power supply and adjust it to high frequency and high current to excite the electromagnetic resistance composite coil, preheating and softening the substrate and the remaining materials on the spinning screw and spinning sleeve;

[0022] S2: In the welding manufacturing process, based on the thinning amount, the feeding amount is slightly greater than or equal to the thinning volume of the material. The AC power supply excites the electromagnetic resistance composite coil with a low-frequency current to adjust the heat input distribution of the joint. The joint and the fed material are changed to a plastic state through friction, shearing and extrusion of the stirring parts and finally filled on the joint surface, realizing a non-thinning welding method.

[0023] An additive manufacturing method is implemented based on a friction stir processing device, and the method comprises the following steps:

[0024] S1: Preheating stage: Turn on the AC power supply and adjust it to high frequency and high current to excite the electromagnetic resistance composite coil to preheat and soften the remaining material on the spinning screw and spinning sleeve;

[0025] S2: In the additive manufacturing process, based on the volume of the additive, the feed amount is slightly greater than or equal to the volume of the additive. The rotating main shaft drives the spinning screw and the stirring component to rotate. The spinning screw rubs, shears and squeezes the particles into a plastic state and finally deposits them on the substrate or the previous deposition layer; in the additive process, the AC power supply excites the electromagnetic resistance composite coil with a low-frequency current to adjust the heat input and the electromagnetic force to adjust the distribution of the heat input of the additive manufacturing structure and apply electromagnetic force to the weak bonding area of the tool edge to achieve continuous and high-quality solid-phase additive manufacturing; in the additive manufacturing process, the volume V1 of the feed material must be kept greater than or equal to the volume V2 of the additive, and the type of feed material can also be adjusted by the proportion of the feed wire to achieve composite material additive manufacturing.

[0026] Furthermore, when performing additive manufacturing of composite materials with honeycomb structures, the trajectory of the single-layer deposited honeycomb composite material must meet the conditions of a wavy non-closed Euler path. During deposition, adjacent paths are only repeatedly deposited at the vertices, and the wire feeding is briefly stopped in the vertex area. The stir friction processing path is formed in one time within the same plane; when adjacent layers are deposited, deposition is adopted in the opposite direction.

[0027] An energy control method is implemented based on a friction stir processing device, specifically including the following control methods:

[0028] a: Obtain the optimal power range of all motors (except the guillotine rotary motor) input under the optimal performance of the friction stir processing process through the motor power detector, P0=P1+P2…P n -P 损 ; Among them: P1, P2…P n The serial number represents the input power of different spindle motors, P 损 is all the energy except that transferred to the stirring mechanism area;

[0029] b: Obtain the physical parameters of the electromagnetic resistance composite coil and determine the input power of the spinning sleeve and the rotating drive assembly as P out ;

[0030] c: By adjusting the input power of the added electromagnetic resistance coil, the tensile strength of the solid phase stirring welding / manufacturing structure is obtained by coordinating the dynamic magnetic field to obtain the electromagnetic power P when the bonding strength is high. out0 ;

[0031] d: When the solid phase stirring motor starts, the input power P of the electromagnetic resistance composite coil is out Adjust to the maximum setting to soften the metal sufficiently to facilitate the rotation and cutting of the tool;

[0032] e: The energy input from the electromagnetic resistance composite coil to the workpiece during the actual solid-phase mixing manufacturing process is P out0 The power P that the motor inputs to the workpiece 实时 Reduced, but the real-time power P of the material 实时 =P1+P2…P n -P 损 +P out0 Always in the optimal power range of P0. When encountering material loss or oxide accumulation or upset force increase, the total energy exceeds the optimal power range of P0. Adjust the voltage or current of the coil power supply to P0. 实时 In the optimal power range of P0, high-quality and stable solid phase friction stir welding and additive manufacturing are achieved.

[0033] The technical solution of the present invention realizes the immediate addition of materials after a short "furnace stop" through the cooperation of an electromagnetic resistance composite coil and a shear wire feeding mechanism. An electromagnetic resistance composite coil with adjustable current size and frequency is set on the outside of the spinning sleeve, and a variable magnetic field strength is excited by the principle of electromagnetic induction. This design can not only achieve precise adjustment of the heat input to the tool and joint area through the induced current, solving the problem of aluminum alloy and other materials blocking the feeding channel after the additive stops, but also generate longitudinal electromagnetic force through the interaction of the induced magnetic field and the coil magnetic field, and efficiently stir the metal in the deposition area, fundamentally improving the interface bonding strength. At the same time, combined with the power detection device, the device can regulate the input energy in real time, avoid defects and relieve residual stress, and significantly reduce the motor starting torque, extend the service life of the equipment, and provide a new solution for the development of metal additive manufacturing and stir friction welding technology. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] In order to more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the specific embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0035] Figure 1 This is a schematic diagram of the overall structure of Example 1 of the present invention.

[0036] Figure 2 for Figure 1 A magnified view of the structure at point A.

[0037] Figure 3 for Figure 1 A magnified view of the structure at point B.

[0038] Figure 4 It is the front view and side view of the wire feeding mechanism of the present invention.

[0039] Figure 5 Schematic diagram of the structure of three forms of spinning sleeves in the present invention.

[0040] Figure 6 Schematic diagram of the structure of three forms of stirring components in the present invention.

[0041] Figure 7 This is a schematic diagram of the overall structure of Example 2 of the present invention.

[0042] Figure 8 This is a schematic structural diagram of a stirring component in Example 4 of the present invention;

[0043] Figure 9 This is a schematic diagram of the composite material solid phase additive structure of the present invention;

[0044] Figure 10 Schematic diagram of the trajectory path during additive manufacturing of the honeycomb structure of the present invention.

[0045] Figure 11 This is a schematic diagram of the time-varying magnetic field heating and electromagnetic stirring control process of the present invention.

[0046] Explanation of the accompanying symbols: 1-rotating main shaft, 2-stationary housing, 3-wire cutting feeding mechanism, 4-knife handle, 5-spinning screw, 6-spinning sleeve, 601-feeding port, 602-wire cutting port, 7-stirring component, 701-center stirring needle, 702-inclined groove, 703-shoulder, 704-edge stirring needle, 8-electromagnetic resistance composite coil, 9-insulating ring, 10-motor power detector, 11-wire feeder, 12-wire material, 13-hopper, 14-cutter disc, 15-bearing seat, 16-wire cutting motor, 17-wire guide sleeve, 18-medium conveyor, 19-guide pipe, 20-guide pipe, 21-hopper, 22-support frame, 23-knife holder. DETAILED DESCRIPTION

[0047] The following will clearly and completely describe the technical solutions of the present invention in conjunction with the embodiments. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0048] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise" and the like to indicate directions or positional relationships based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operate in a specific direction, and therefore should not be understood as limiting the present invention.

[0049] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the said features. In the description of the present invention, "multiple" means two or more, unless otherwise clearly and specifically defined. In addition, the terms "installed", "connected", and "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be an indirect connection through an intermediate medium, or it can be a communication between the two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to the specific circumstances.

[0050] Example 1

[0051] like Figures 1-6As shown, the present invention provides a stir friction processing device, including a stationary shell 2, a spinning sleeve 6 and a rotary drive assembly, the spinning sleeve 6 is fixedly installed at the bottom end of the stationary shell 2 by screws, and a spinning screw 5 is rotatably installed in the spinning sleeve 6, the spinning screw 5 and the spinning sleeve 6 cooperate with each other to realize the downward conveying of the material, and the top of the spinning screw 5 is fixedly connected to the output end of the rotary drive assembly through a tool handle 4, wherein: the rotary drive assembly includes a rotating spindle 1 and a first drive motor for driving the rotating spindle 1 to rotate, the first drive motor is connected to a first motor power detector 10, and the displacement drive mechanism for driving the rotating drive assembly to move is connected to multiple second motor power detectors, each second motor power detector corresponds to an executive motor, for example: when a heavy-load robot is used, the executive motors at each joint of the robot arm are respectively connected to a second motor power detector, the stationary shell 2 is covered on the outside of the rotating spindle 1, the tool handle 4 is inserted into the bottom end fixed to the rotating spindle 1, and the top of the spinning screw 5 is fixed to the bottom end of the tool handle 4 by screws.

[0052] A stirring member 7 is fixedly mounted at the bottom end of the spinning screw 5, integrally formed with the spinning screw 5. In this embodiment, the stirring member 7 is a welded, non-thinning stirring structure comprising a central stirring pin 701 located at the center of the bottom of the spinning screw 5 and an inclined groove 702 or shoulder 703 located at the bottom edge of the spinning screw 5. The shoulder 703 is a flat or concave structure. When the inclined groove 702 is used, the radial edge of the inclined groove 702 is tilted toward the direction of rotation and forms a radial angle greater than 30° with the root extension.

[0053] A feed port 601 is provided on the side wall of the spinning sleeve 6, and the feed port 601 is connected to the bottom of the hopper 13 of the external wire chopping feeding mechanism 3. If the spinning sleeve 6 is provided with both a feed port 601 and a wire chopping port, if an external wire chopping feeding mechanism 3 is used for feeding, the wire chopping port can be temporarily blocked. If an internal wire chopping is used, the feed port can be blocked. In this embodiment, an external wire chopping feeding mechanism 3 is used, and the wire chopping feeding mechanism 3 includes a hopper 13, a shear disc 14 and a wire feeder 11. In order to lift the hopper 13 to a certain height, a support frame 22 is also provided. The hopper 13 is installed on the support frame 22. The bottom end of the hopper 13 is an inclined hopper 21, and the bottom end of the hopper 21 is connected to the feed port 601 through a guide pipe 20. The rotating shaft of the cutter disc 14 is rotatably installed inside the silo 13 through the bearing seat 15, and the bearing seat 15 is fixedly installed on the support frame 22. The outside of the silo 13 is fixedly installed with a wire chopper motor 16 for driving the cutter disc 14 to rotate; the side of the silo 13 away from the wire chopper motor 16 is provided with multiple feed ports arranged in a circular array, and each feed port is provided with a wire guide sleeve 17. The wire feeder 11 conveys the wire 12 to the cutter disc 14 through the wire guide sleeve 17, and the wire 12 fed into the silo 13 is cut into granules by the blade on the cutter disc 14. In order to improve the efficiency of feeding particles into the spinning sleeve 6, a medium conveyor 18 is also provided in this scheme. The medium conveyor 18 is connected to the hopper 13 of the wire feeding mechanism 3 through the guide tube 19. The medium conveyed by the medium conveyor 18 is: liquid nitrogen, dry ice, helium, neon, argon and other gases or water, a mixture of water and alloy powder, etc., which plays the role of cooling the shear blade and promoting the movement of the material. The medium conveyor 18 is connected to the wire feeding mechanism to play the role of cooling the shear blade and promoting the movement of the particle material.

[0054] The outer side of the spinning sleeve 6 is covered with an electromagnetic resistance composite coil 8 with adjustable current magnitude and frequency. The outer side or inner side of the electromagnetic resistance composite coil 8 is wrapped with a heat insulation ring 9.

[0055] When performing non-thinning welding: During the initial preheating phase, the AC power supply is turned on and the electromagnetic resistance composite coil 8 is energized to preheat and soften the substrate and the material remaining between the spinning screw 5 and the spinning sleeve 6. This solves the problem of continuous feeding of the material due to root blockage in the initial stage. During the steady-state phase, it is necessary to always maintain the volume V1 of the fed material ≥ the volume V2 of the added material, and preferably the volume V1 of the fed material = the volume V2 of the added material. The material is pre-processed into granules by the guillotine feeding structure, and the granules are simultaneously fed into the gap between the spinning screw 5 and the spinning sleeve 6 through the feeding port 601 under the action of the mechanical conveyor and the gravitational potential energy system.

[0056] During the additive manufacturing process, in the preheating stage, the AC power supply is adjusted to a high frequency and high current to excite the electromagnetic resistance composite coil, so that the electromagnetic resistance composite coil 8 applies electromagnetic force to the weak bonding area at the edge of the additive manufacturing tool, preheating and softening the residual material on the spinning screw and spinning sleeve. During the additive manufacturing process, based on the volume of the additive material, the feed amount is slightly greater than or equal to the volume of the additive material. The rotating spindle 1 drives the spinning screw 5 and the stirring component 7 to rotate. The spinning screw 5 rubs, shears, and squeezes the particles into a plastic state, and finally deposits them on the substrate or the previous deposition layer. During the additive process, the AC power supply excites the electromagnetic resistance composite coil with a low frequency current to adjust the heat input and electromagnetic force distribution of the additive manufacturing structure and apply electromagnetic force to the weak bonding area at the edge of the tool, achieving continuous and high-quality solid-phase additive manufacturing. During the additive manufacturing process, the volume V1 of the feed material must be kept greater than or equal to the volume V2 of the additive material. The type of feed material can also be adjusted by the ratio of the feed wire to achieve composite material additive manufacturing.

[0057] When the wire feeding mechanism 3 is working: a variety of different materials can be fed through the wire feeder 11 to achieve material additive. The types of materials can be: metal materials such as iron, aluminum, magnesium, copper, titanium, and non-metallic matrix materials such as thermoplastic resin materials, thermosetting resin materials, ceramics, graphite, etc.

[0058] like Figure 9 As shown, the composite materials produced are divided into: sandwich composite materials, core composite materials, fine-grained composite materials and mixed composite materials according to their structures. The production methods of different types of composite materials are as follows: According to the type of composite material: select to feed material A, or feed material B, or feed multiple wires synchronously: feed material A for multiple depositions to deposit a flat plate structure or a single wall of material A, and then feed material B for multiple depositions on this basis, thereby depositing a solid sandwich plate composite material A-1 or a reinforcement composite material A-2, and then perform multiple depositions of material A on material B to form a composite structure shown in A-3, or perform multiple depositions of material B on the reverse side of the bottom end of the material A structure. The composite structure shown in A-4 is formed to realize horizontal solid sandwich composite materials. By alternating wire feeding between passes in the same horizontal dimension and maintaining alternating wire feeding on different horizontal planes, the longitudinal solid sandwich composite material A-5 can be produced. In addition, the number of wire feeding alternations on the same horizontal plane is not unique. Adjacent layers are deposited alternately in the vertical direction, and the number of deposition passes is consistent. The number of layers is an even number of four or more, which can realize the production of isotropic solid composite materials A-6. By controlling the wire feeding amount through the double-wire feeding method, the solid fine-grained composite material A-7 can be produced. The wire feeding amount can also be controlled through the three-wire and multi-wire feeding methods to realize the production of mixed composite materials A-8 within the solid layer.

[0059] By using the feeding method of synchronous double wires in the wire cutting and feeding mechanism 3, different feeding methods are selected for adjacent layers, and the materials of adjacent layers are kept in the form of ABAB or ABCABC, so as to realize the interlayer hybrid composite material. By analogy, adjusting the above feeding method can realize the solid interlayer hybrid composite material or the solid sandwich hybrid composite material. For the production of the hollow structure composite material, the deposition trajectory of a single layer must meet the condition of a non-closed Euler path in the shape of a wave, and only the head and tail of all vertices can be two singular points, and the others are even points. During deposition, only the vertices are repeatedly deposited between adjacent paths, and the wire feeding is briefly stopped in the vertex area: such as along Figure 10 The rectangular honeycomb structure formed by the path shown is used to make a single layer of the honeycomb structure on the horizontal plane of the substrate. The trajectory sequence is from 1 to 135, and the reverse deposition is used for the next layer, from 135 to 1, and for the next layer, from 1 to 135, and so on. The multi-layer stacking realizes the additive manufacturing of the honeycomb structure, and the top splint is welded or glued or riveted, and finally the production of the hollow structure composite material is realized.

[0060] In this embodiment: the major diameter of the thread of the spinning screw 5 is D2, the minor diameter is D1, the width of the screw top is D T and the width of the screw bottom is D B and the pitch is D P =D T +D B The diameter of the wire 12 is D, and the thread is distributed upward from the bottom of the spinning screw 5, and it satisfies the following relationship: (D2 - D1) / 2 > D / 2, 0.1*D < D B < 5*D, and the total thread length does not exceed 30*D when the pitch is constant P ; when the pitch is variable, it satisfies the following relationship: 1*D < D P < 9*D, the pitch can increase from small to large or decrease from large to small, and the total thread length < 200 mm; the central composite through hole inside the spinning sleeve 6 is divided into a supply part and a spinning part. The feeding port 601 is arranged in the supply part of the spinning sleeve 6, and the inner diameter of the inner wall corresponding to the supply part is D3, and it satisfies the following relationship: the maximum outer diameter cut by the replaceable blade edge < D3 < the outer diameter of the replaceable blade edge + 2 mm.

[0061] The inner wall surface of the spinning sleeve 6 needs to be polished, and its inner diameter is a variable diameter structure. Assuming that the inner diameter of the part responsible for spinning inside the spinning sleeve 6 is D4, the following relationship needs to be satisfied: D2 + 0.1 mm < D4 < D2 + 20 mm. The inner wall diameter of the spinning sleeve 6 can be set from top to bottom as: the inner diameter decreases from large to small, increases from small to large, or decreases from large to small and then to the second largest.

[0062] The materials used in the middle of this embodiment can be wire 12, strip, or powder. These materials can be metals such as iron, aluminum, magnesium, copper, and titanium, as well as non-metallic matrix materials such as thermoplastic resins, thermosetting resins, ceramics, and graphite. The materials can be one or more. The reinforcing alloy powder can be metal powders such as scandium, zirconium, niobium, and titanium, or non-metallic materials such as carbon nanotubes, graphene nanosheets, and ceramic particles. The reinforcing base powder should account for no more than 8% of the total feed volume, and the powder diameter should be micrometers or less.

[0063] Example 2

[0064] like Figure 7 As shown, the technical features that distinguish this embodiment from Example 1 are as follows: the inner diameter of the spinning sleeve 6 gradually decreases in height from top to bottom, a plurality of cutting openings 602 are provided on the side wall of the spinning sleeve 6 in the height direction, a multi-layered knife seat 23 is fixedly installed on the knife handle 4 at the position corresponding to the cutting openings 602, a plurality of replaceable blades are installed on the knife seat 23 at equal intervals along its circumference by screws, the installation stations for installing the blades on two adjacent layers of knife seats 23 are staggered along the circumferential direction, and the type of blade can be adaptively selected according to the type of material being fed in. When multiple materials are fed in simultaneously, each material corresponds to a knife seat 23 at a different height position, realizing the feeding of composite materials, and each material is cut into granules by the blades on different knife seats 23.

[0065] The diameter of the shearing mouth 602 is in the range of 1.0*D to 2.0*D, the axial position of the shearing mouth 602 is within the axial cutting range of the replaceable blade, and the gap between the inner wall of the spinning sleeve 6 and the rotating blade corresponding to the position of the shearing mouth 602 is within 0.05 to 2 mm. The surface of the shearing mouth 602 is covered with an electroplated coating such as titanium nitride coating, titanium carbide coating, aluminum oxide coating, tungsten carbide or a multi-layer coating (titanium nitride coating and titanium carbide coating, aluminum oxide coating and titanium nitride coating), or a vapor-deposited solid material such as metal, ceramic or other compounds, or the blade is directly selected from cemented carbide, or metal powder and diamond particles sintered (PCD).

[0066] A medium inlet is provided on the stationary shell 2, and the medium inlet is connected to the medium conveyor 18 through the guide tube 19. The medium conveyor 18 in this embodiment is an air pump. When in use, the guide tube 19 is connected to the stationary shell 2, and the other end is connected to the air pump. The introduced gas is blown to the shearing mouth 602 of the spinning sleeve 6 to achieve the cooling effect.

[0067] Example 3

[0068] like Figure 6The structure shown on the far right of the embodiment is different from that of embodiment 1 or 2 in that the stirring component 7 is an additive stirring structure, which includes a central stirring needle 701 located at the center of the bottom of the spinning screw 5 and edge stirring needles 704 located at the bottom edge of the spinning screw 5 and arranged in a circular array. The length of the edge stirring needle 704 is greater than the thickness of a single additive, the length of the central stirring needle 701 is greater than the length of the edge stirring needle 704, and the width of the central stirring needle 701 and the edge stirring needle 704 is at least 1 / 15 of the diameter of the shaft shoulder. The geometric shape of the edge stirring needle 704 can be circular, rectangular, trapezoidal, prismatic, etc. The stirring needles do not interfere with each other.

[0069] Example 4

[0070] like Figure 8 As shown, the technical feature that distinguishes this embodiment from embodiments 1-3 is that the surface of the central stirring needle 701 may be provided with threads, and the axial component of the thread rotation shearing force is consistent with the direction of penetration into the plate.

[0071] The energy control method when using the electromagnetic resistance composite coil 8 in this technical solution includes:

[0072] a. Obtain the total power range of all motors (except the guillotine motor 16) input under the optimal solid-phase mixing process parameters through the power meter

[0073] Among them, P1, P2…P n The serial number represents the input power of different spindle motors, P 欧损 is the power of the motor's ohmic loss, P 维磁 is the power consumed by the motor to maintain the magnetic field, U is the real-time voltage of the corresponding motor input, I is the real-time current of the corresponding motor input, Φ is the power factor of the corresponding motor, R is the total internal resistance of the corresponding motor, L is the total inductance of the corresponding motor, W is the total weight of the moving electric spindle, and v is the average speed of the electric spindle;

[0074] b. Obtain the physical parameters of the coil, according to η=(P out / P in )*100%=R2 / (R1+R2), P in =u*i*cos(Φ), cos(Φ)=R / sqrt(R 2 +X 2 ), R1 is the equivalent resistance of the coil conductor itself, R2 is the resistance of the coil converted from the power consumed by the workpiece, R=R1+R2, X is the total inductive reactance generated between the energized coil, the heated workpiece and the air gap, P out is the power output of the coil, P inis the power input to the induction coil, u is the effective value of the power input voltage, i is the effective value of the power input current, and the energy formula P of the coil input to the workpiece is derived. out =R2*u*i*R / (sqrt(R2+X2)*(R1+R2));

[0075] c. By comparing the tensile strength of the structure manufactured by the coordinated dynamic magnetic field solid phase stirring under different electromagnetic parameters, the electromagnetic power at high bonding strength is obtained as P out0 ;

[0076] d. During the solid phase stirring motor startup phase, the input power P of the electromagnetic resistance composite coil 8 is out Adjust to the maximum setting to soften the metal sufficiently to facilitate the rotation and cutting of the tool;

[0077] e. In the actual solid-phase stirring manufacturing process, the energy input from the coil to the workpiece is P out0 The power P input by the motor to the workpiece is reduced in real time, but the real-time power P acting on the material is Always in the optimal power range of P0. When encountering material loss or oxide accumulation or upset force increase, the total energy exceeds the optimal power range of P0. Adjust the voltage or current of the coil power supply to P0. 实时 In the optimal power range of P0, high-quality and stable solid phase friction stir welding and additive manufacturing are achieved.

[0078] Figure 11 As shown, to address the issues of material blockage after furnace shutdown, which hinders continuous feeding, and the weak bonding caused by the oxide film between the deposited material and the substrate on both sides of the additive component, high current and high frequency are adjusted during the preheating and final stages to soften the remaining material, enabling continuous feeding and clearing of the material, while also avoiding high starting torque that could damage the spindle. During welding or additive manufacturing, low-frequency current is used to reduce heat input to the spindle, primarily applying electromagnetic force to strengthen the interface between the deposited material on both sides of the additive component.

[0079] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the above embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A friction stir processing device, characterized in that It includes a spinning sleeve and a rotary drive assembly, a spinning screw is rotatably installed in the spinning sleeve, the top end of the spinning screw is fixedly connected to the output end of the rotary drive assembly through a knife handle, and a stirring component is fixedly provided at the bottom end of the spinning screw; the outer side of the spinning sleeve is covered with an electromagnetic resistance composite coil with adjustable current size and frequency, and a feeding port and / or a wire cutting port is opened on the side wall of the spinning sleeve.

2. The friction stir processing device according to claim 1, wherein It also includes a stationary shell, the spinning sleeve is fixedly installed at the bottom end of the stationary shell, the rotation drive assembly includes a rotating spindle and a first drive motor for driving the rotating spindle to rotate, the first drive motor is connected to a first motor power detector, and the displacement drive mechanism for driving the rotation drive assembly to move is connected to multiple second motor power detectors, each of the second motor power detectors corresponds to an execution motor, the stationary shell is covered on the outside of the rotating spindle, and the tool handle is installed at the bottom end of the rotating spindle.

3. The friction stir processing device according to claim 2, wherein The feed port is connected to the hopper of the wire feeding mechanism, and the wire feeding mechanism includes a hopper, a cutter disc, a medium conveyor and a wire feeder. The cutter disc is rotatably installed inside the hopper, and a wire chopper motor for driving the cutter disc to rotate is fixedly installed outside the hopper; a plurality of feed ports are arranged in a circular array on the side of the hopper away from the wire chopper motor, and each feed port is provided with a wire guide sleeve, and the wire feeder conveys the wire material to the cutter disc through the wire guide sleeve and cuts it into granules; the medium conveying is connected to the hopper through a guide pipe.

4. The friction stir processing device according to claim 1, wherein A heat insulation ring is provided inside or outside the electromagnetic resistance composite coil.

5. The friction stir processing device according to claim 1, wherein The stirring component is a welded non-thinning stirring structure, which includes a central stirring needle located at the center of the bottom of the spinning screw and an inclined groove or shoulder located at the edge of the bottom of the spinning screw. The shoulder is a flat or concave structure.

6. The friction stir processing device according to claim 1, wherein The stirring component is an additive stirring structure, which includes a central stirring pin located at the center of the bottom of the spinning screw and an edge stirring pin located at the edge of the bottom of the spinning screw and arranged in a circular array. The length of the edge stirring pin is greater than the thickness of a single additive pass, the length of the central stirring pin is greater than the length of the edge stirring pin, and the width between the central pin and the edge pin is at least 1 / 15 of the diameter of the shaft shoulder.

7. The friction stir processing device according to claim 3, wherein The medium conveyor is an air pump. The particles formed after the wire is cut are transported from the guide tube to the inside of the spinning sleeve under the gravity potential energy and the airflow provided by the air pump.

8. The friction stir processing device according to claim 3, wherein The bottom end of the silo is a hopper that is arranged obliquely, and the bottom end of the hopper is connected to the feeding port through a material guide pipe.

9. The friction stir processing device according to claim 2, wherein A plurality of layers of tool holders are fixedly installed on the tool handle at the position of the shearing mouth of the spinning sleeve. A plurality of blades are installed on each layer of the tool holder at equal intervals along its circumference. The installation stations for installing the blades on two adjacent layers of the tool holders are staggered along the circumferential direction.

10. The friction stir processing device according to claim 9, wherein A medium inlet is provided on the stationary housing, and the medium inlet is communicated with the medium conveyor through a flow guide pipe.

11. A non-thinning welding method, characterized in that: The method is implemented based on the friction stir processing device according to any one of claims 1 to 10, and comprises the following steps: S1: Preheating stage: Turn on the AC power supply and adjust it to high frequency and high current to excite the electromagnetic resistance composite coil, preheating and softening the substrate and the remaining materials on the spinning screw and spinning sleeve; S2: In the welding manufacturing process, based on the thinning amount, the feeding amount is slightly greater than or equal to the thinning volume of the material. The AC power supply excites the electromagnetic resistance composite coil with a low-frequency current to adjust the heat input distribution of the joint. The joint and the fed material are changed to a plastic state through friction, shearing and extrusion of the stirring parts and finally filled on the joint surface, realizing a non-thinning welding method.

12. An additive manufacturing method, characterized in that: The method is implemented based on the friction stir processing device according to any one of claims 1 to 10, and the method comprises the following steps: S1: Preheating stage: Turn on the AC power supply and adjust it to high frequency and high current to excite the electromagnetic resistance composite coil to preheat and soften the remaining material on the spinning screw and spinning sleeve; S2: In the additive manufacturing process, based on the volume of the additive material, the feed amount is slightly greater than or equal to the volume of the additive material. The rotating spindle drives the spinning screw and the stirring component to rotate. The spinning screw rubs, shears and squeezes the particles into a plastic state and finally deposits them on the substrate or the previous deposition layer; During the additive process, the AC power supply excites the electromagnetic resistance composite coil with a low-frequency current to adjust the heat input and the electromagnetic force to adjust the distribution of the heat input of the additive manufacturing structure and apply electromagnetic force to the weak bonding area of the tool edge to achieve continuous and high-quality solid-phase additive manufacturing. During the additive manufacturing process, the volume V1 of the feed material must be kept greater than or equal to the volume V2 of the additive material. The type of feed material can also be adjusted by the proportion of the feed wire to achieve composite material additive manufacturing.

13. The additive manufacturing method according to claim 12, characterized in that: When performing additive manufacturing of composite materials with honeycomb structures, the trajectory of a single-layer deposited honeycomb composite material must meet the conditions of a wavy non-closed Euler path. During deposition, adjacent paths are only repeatedly deposited at the vertices, and wire feeding is briefly stopped in the vertex area. The stir friction processing path is formed in one go within the same plane; adjacent layers are deposited in opposite directions.

14. An energy control method, characterized in that: The method is based on the friction stir processing device according to any one of claims 1 to 10, and specifically includes the following control method: a: Obtain the optimal power range of all motors (except the guillotine rotary motor) input under the optimal performance of the friction stir processing process through the motor power detector, P0=P1+P2…P n -P 损 ; Among them: P1, P2…P n The serial number represents the input power of different spindle motors, P 损 is all the energy except that transferred to the stirring mechanism area; b: Obtain the physical parameters of the electromagnetic resistance composite coil and determine the input power of the spinning sleeve and the rotating drive assembly as P out ; c: By adjusting the input power of the added electromagnetic resistance coil, the tensile strength of the solid phase stirring welding / manufacturing structure is obtained by coordinating the dynamic magnetic field to obtain the electromagnetic power P when the bonding strength is high. out0 ; d: When the solid phase stirring motor starts, the input power P of the electromagnetic resistance composite coil is out Adjust to the maximum setting to soften the metal sufficiently to facilitate the rotation and cutting of the tool; e: The energy input from the electromagnetic resistance composite coil to the workpiece during the actual solid-phase mixing manufacturing process is P out0 The power P that the motor inputs to the workpiece 实时 Reduced, but the real-time power P of the material 实时 =P1+P2…P n -P 损 +P out0 Always in the optimal power range of P0. When encountering material loss or oxide accumulation or upset force increase, the total energy exceeds the optimal power range of P0. Adjust the voltage or current of the coil power supply to P0. 实时 In the optimal power range of P0, high-quality and stable solid phase friction stir welding and additive manufacturing are achieved.

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