Consumable friction stir welding device and welding method

Abstract

The present invention discloses a consumable friction stir welding device and welding method, which belongs to the field of welding technology, and comprises: a workbench; a movable gantry; a movable beam located in the movable gantry and capable of sliding relative to the movable gantry in a vertical direction; a first driving unit, for driving the movable beam to slide relative to the movable gantry; a hollow sleeve, the first end of the sleeve being fixedly connected to the movable beam, and the second end of the sleeve being a free end; a hollow shaft rotatably connected to the sleeve; a core material, the core material passing through the center hole of the hollow shaft; a second driving unit, for driving the hollow shaft to rotate along its center axis, thereby driving the core material to rotate; a pressure applying unit, which is arranged on the movable gantry. The present invention can accurately adjust the feeding direction and feeding distance of the core material according to welds of different sizes, adjust the depth of the core material in the weld, preheat the core material and the weld in advance, and flatten and protect the weld in time.

Description

Technical Field

[0001] The invention belongs to the technical field of welding, and in particular relates to a consumable friction stir welding device and a welding method. Background Art

[0002] Friction stir welding (FSW) is a new solid-state joining technology invented by the Welding Institute in the UK in 1991. The process involves a stirring head, consisting of a shoulder and a stirring pin, rotating at high speed while being inserted into the weld and advancing forward. Frictional heat plasticizes the materials to be welded, causing plastic flow driven by the stirring head. The weld is then formed by the forging action of the shoulder, achieving a solid-state connection. This technology offers numerous advantages, including minimal microstructural change, low residual stress, and minimal deformation.

[0003] Friction stir welding can weld materials such as aluminum alloys, magnesium alloys, titanium alloys, and steel, and is widely used in aerospace, transportation, construction, and other fields. During use, friction welding equipment requires replacing the stirring needle, limiting and securing the welded parts, accurately positioning and feeding the stirring needle, and timely flattening and protection of the weld seam.

[0004] However, the existing friction stir welding device has a small stirring needle size, a short welding distance, a high welding cost, a poor ability of the limiting mechanism to fix the position of the welded parts, insufficient preheating of the stirring needle and the weld, and an inaccurate feeding direction and feeding distance of the stirring head. The weld cannot be flattened and protected in time, resulting in misalignment of the welded parts and the weld during the welding process, low welding efficiency, and poor weld forming quality. Summary of the Invention

[0005] The purpose of the present invention is to provide a stir friction welding device and welding method with a long welding distance, low welding cost, the ability to accurately fix the position of the welded parts, and the ability to accurately adjust the feeding direction and feeding distance of the core material according to welded parts of different sizes. At the same time, the depth of the core material in the weld can be adjusted, and the core material and weld can be preheated in advance, flattened in time, and protected.

[0006] In order to achieve the purpose of the present invention, the technical solution adopted by the present invention is:

[0007] A consumable friction stir welding device, comprising:

[0008] Workbench, used to place parts to be welded;

[0009] A mobile gantry, comprising two oppositely disposed vertical beams and a crossbeam fixedly connected between the two vertical beams; the vertical beams are slidably connected to the upper end of the workbench;

[0010] a movable beam located in the movable gantry and capable of sliding relative to the movable gantry in a vertical direction;

[0011] A first driving part, used for driving the movable beam to slide relative to the movable gantry;

[0012] a hollow sleeve, wherein a first end of the sleeve is fixedly connected to the movable beam, and a second end of the sleeve is a free end, and the free end is located on a side of the movable beam away from the crossbeam;

[0013] a hollow shaft rotatably connected to the sleeve, wherein a first end of the hollow shaft is located in the hollow cavity of the sleeve, and a second end of the hollow shaft passes through the moving beam and extends outside the moving beam;

[0014] A core material, wherein the core material passes through the central hole of the hollow shaft, a first end of the core material extends to the outside of the hollow shaft and is located between the cross beam and the moving beam; a second end of the core material extends to the outside of the sleeve and contacts the workpiece to be welded;

[0015] A second driving part is used to drive the hollow shaft to rotate along its central axis, thereby driving the core material to rotate;

[0016] A pressure-applying portion is provided on the movable gantry and is used to apply pressure to the first end of the core material to ensure that the second end of the core material is always in contact with the workpiece to be welded.

[0017] Furthermore, it also includes a flattening and protection mechanism, which includes:

[0018] a first flattening rod and a second flattening rod, wherein the first flattening rod is a hollow structure, a first end of the first flattening rod is connected to the moving beam via a first flange, a first end of the second flattening rod is at least partially slidably inserted into the first flattening rod, and a second end of the second flattening rod is provided with a flange near an end position;

[0019] A spring is arranged between the flange and the second end face of the first flattening rod, and a square frame is arranged at the second end of the second flattening rod, and a roller is rotatably connected to the side of the square frame away from the second flattening rod; a blowing hole is arranged between the second end of the second flattening rod and the flange, and the outlet direction of the blowing hole points to the welded seam so as to protect the welded seam with shielding gas.

[0020] Furthermore, a preheating mechanism is included, and the preheating mechanism includes a heating wire wound around the inner wall of the sleeve, and the heating wire is used to preheat the core material in advance after power is applied.

[0021] Furthermore, guide rails are provided on both sides of the workbench, and a slider is provided at the lower end of the vertical beam, and the guide rails and the slider are slidably matched.

[0022] Furthermore, it also includes a ball screw transmission mechanism, which includes a ball screw rotatably connected to the workbench and a screw nut arranged on the vertical beam.

[0023] Furthermore, the first driving part is a hydraulic telescopic rod, the fixed end of the hydraulic telescopic rod is fixedly connected to the crossbeam, and the driving end of the hydraulic telescopic rod is fixedly connected to the movable beam via a second flange.

[0024] Furthermore, the second driving part includes a motor arranged on the moving beam, a first gear arranged at the output end of the motor, a second gear is arranged at the first end of the hollow shaft, and the first gear is meshed with the second gear.

[0025] Furthermore, it also includes a clamping block, a limit block and a blocking block relatively arranged on the workbench, the limit block and the blocking block are used to position the parts to be welded; the clamping block is arranged on the workbench in an adjustable height by bolts, and is used to clamp the parts to be welded.

[0026] Furthermore, it also includes a unloading mechanism, which is located on one side of the workbench and is used to place the welded parts for cooling.

[0027] A welding method using any of the above-mentioned consumable friction stir welding devices comprises the following steps:

[0028] S10. Place the workpiece to be welded on the workbench and fix it with a limit block, a pressing block and a blocking block;

[0029] S20, starting the hydraulic telescopic rod to push the movable beam downward, so that the second end of the sleeve and the core material extends into the groove of the weld;

[0030] S30, pressing the roller at the top of the flattening and protection mechanism against the surface of the workpiece to be welded under the action of a spring;

[0031] S40, energize the heating wire in the sleeve to start preheating the core material and the weld;

[0032] S50, after preheating is completed, the air hole is opened, and the motor is turned on to start the core material rotating;

[0033] S60, the pressure applying part applies pressure to the first end of the core material, and after the second end of the core material contacts the surface of the workpiece to be welded, friction between them generates heat;

[0034] S70, when the portion of the second end of the core material that is higher than the sleeve is gradually worn away due to friction, and the second end of the sleeve abuts against the surface of the weldment, moving the gantry at a preset feed speed;

[0035] S80, blow out shielding gas from the blowing hole to protect the weld, and the roller flattens the weld to ensure the quality of the weld;

[0036] S90, open the pressing block and place the weldment on the unloading mechanism for cooling;

[0037] S100, return the mobile gantry to the initial position and reload the material to start the next round of welding task.

[0038] Beneficial effects of the present invention:

[0039] Compared with the existing technology, the present invention has a longer welding distance and lower welding cost, can accurately fix the position of the welded parts, can accurately adjust the feeding direction and feeding distance of the core material according to the different sizes of welded parts, adjust the depth of the core material in the weld, can preheat the core material and the weld in advance, and flatten and protect the weld in time, effectively improving the weld position accuracy, welding efficiency and the forming quality of the welded parts. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] Figure 1 It is a schematic diagram of the overall structure of the present invention;

[0041] Figure 2 This is a front view of the overall structure of the present invention;

[0042] Figure 3 It is a structural diagram of the power transmission;

[0043] Figure 4 It is a left side view of the overall structure of the present invention;

[0044] Figure 5 It is a rear view of the overall structure of the present invention;

[0045] Figure 6 It is a top view of the overall structure of the present invention;

[0046] Figure 7 Schematic diagram of preheating structure;

[0047] Figure 8 It is a structural diagram of the core material;

[0048] Figure 9 It is a partial enlarged view of the flattening and blowing protection mechanism;

[0049] In the figure: 1. Support frame; 2. Guide rail; 3. Ball screw; 4. Workbench; 5. Mobile gantry; 6. Hydraulic telescopic rod; 7. Motor; 8. Pressure part; 9. Second flange; 10. Moving beam; 11. Flattening and protection mechanism; 12. Clamping block; 13. Spring; 14. Limit block; 15. Roller; 16. Part to be welded; 17. Hollow shaft; 18. Second gear; 19. Stop block; 20. Sleeve; 21. Core material; 22. Unloading mechanism; 23. Heating wire; 24. Blowing hole. DETAILED DESCRIPTION

[0050] The present invention provides a consumable friction stir welding device and a welding method. The technical solution of the present invention is described in detail below with reference to the accompanying drawings to make it easier to understand and grasp.

[0051] Example 1

[0052] refer to Figure 1-9 , a consumable friction stir welding device, comprising:

[0053] A workbench 4 for placing the workpiece 16 to be welded;

[0054] The mobile gantry 5 includes two vertical beams arranged opposite to each other and a horizontal beam fixedly connected between the two vertical beams; the vertical beams are slidably connected to the upper end of the workbench 4;

[0055] A movable beam 10 located within the movable gantry 5 and capable of sliding vertically relative to the movable gantry 5;

[0056] The first driving part is used to drive the moving beam 10 to slide relative to the moving gantry 5;

[0057] A hollow sleeve 20, wherein a first end of the sleeve 20 is fixedly connected to the moving beam 10, and a second end of the sleeve 20 is a free end, which is located on a side of the moving beam 10 away from the crossbeam;

[0058] a hollow shaft 17 rotatably connected to the sleeve 20 , wherein a first end of the hollow shaft 17 is located in the hollow cavity of the sleeve 20 , and a second end of the hollow shaft 17 passes through the moving beam 10 and extends outside the moving beam 10 ;

[0059] The core material 21 passes through the central hole of the hollow shaft 17. The first end of the core material 21 extends to the outside of the hollow shaft 17 and is located between the crossbeam and the moving beam 10. The second end of the core material 21 extends to the outside of the sleeve 20 and contacts the workpiece 16 to be welded.

[0060] The second driving part is used to drive the hollow shaft 17 to rotate along its central axis, thereby driving the core material 21 to rotate;

[0061] The pressure applying portion 8 is provided on the movable gantry 5 and is used to apply pressure to the first end of the core material 21 to ensure that the second end of the core material 21 is always in contact with the workpiece 16 to be welded.

[0062] In this embodiment, the workbench 4 is fixedly mounted on the upper end of the support frame 1 .

[0063] In this embodiment, the core material 21 is a consumable material, which is composed of a flat cylinder made of the same material as the material to be welded; the sleeve 20 is a support body, and is coaxially matched with the core material 21 through a bearing, and is a non-consumable component; the second end of the core material 21 extends beyond the second end of the sleeve 20 by 0 to 5 mm, preferably 1 to 3 mm, wherein the second end of the sleeve 20 sinks into the surface of the workpiece by 0 to 0.3 mm, preferably 0.2 mm.

[0064] The consumable friction stir welding device provided in this embodiment has a longer welding distance and lower welding cost, and can accurately adjust the feeding direction and feeding distance of the core material according to welded parts of different sizes.

[0065] Example 2

[0066] In order to flatten and protect the weld in a timely manner, this embodiment makes further arrangements based on embodiment 1.

[0067] The consumable friction stir welding device provided in this embodiment further includes a flattening and protection mechanism. The flattening and protection mechanism 11 includes:

[0068] a first flattening rod and a second flattening rod, wherein the first flattening rod is a hollow structure, a first end of the first flattening rod is connected to the moving beam 10 through a first flange, a first end of the second flattening rod is at least partially slidably inserted into the first flattening rod, and a second end of the second flattening rod is provided with a flange near the end position;

[0069] A spring 13 is provided between the flange and the second end face of the first flattening rod, and a square frame is provided at the second end of the second flattening rod. The square frame is rotatably connected to a roller 15 on one side away from the second flattening rod; a blowing hole 24 is provided between the second end portion of the second flattening rod and the flange, and the outlet direction of the blowing hole 24 points to the welded seam so as to protect the welded seam with shielding gas.

[0070] Among them, rollers and blowing holes are provided at the rear of the sleeve 20 to flatten and protect the weld.

[0071] In this embodiment, a receiving cavity is provided in the second flattening rod, the receiving cavity is communicated with the air supply device, and the air blowing hole 24 is communicated with the receiving cavity.

[0072] Example 3

[0073] In order to accurately fix the position of the weld, the depth of the core material in the weld can be adjusted, the core material and the weld can be preheated in advance, and the weld can be flattened and protected in time, effectively improving the weld position accuracy, welding efficiency and the forming quality of the weld. This embodiment is further configured on the basis of Example 2.

[0074] In this embodiment, the first driving part is a hydraulic telescopic rod 6 , the fixed end of the hydraulic telescopic rod 6 is fixedly connected to the crossbeam, and the driving end of the hydraulic telescopic rod 6 is fixedly connected to the moving beam 10 through the second flange 9 .

[0075] By providing the pressing portion 8 at the first end of the core material 21 , the feeding distance of the core material drill 21 in the pressing direction can be controlled.

[0076] In this embodiment, the pressure applying portion 8 is a hydraulic telescopic rod, a hydraulic cylinder, an air cylinder or other force applying mechanisms.

[0077] In this embodiment, the second driving part includes a motor 7 arranged on the moving beam 10, a first gear arranged at the output end of the motor 7, and a second gear 18 is provided at the first end of the hollow shaft. The first gear is engaged with the second gear 18.

[0078] The first gear and the second gear 18 are both bevel gears. The second gear 18 is sleeved on the outside of the first end of the hollow shaft, and the rotational torque of the core material 21 can be controlled by the bevel gear transmission mechanism provided at the end of the core material 21.

[0079] More specifically, the core material 21 is sleeved in a hollow shaft 17 having the same cross-sectional shape as the core material 21 . The hollow shaft 17 passes through a bearing fixed on the moving beam and cooperates with the inner hole of the second gear 18 (bevel gear).

[0080] The consumable friction stir welding device of this embodiment further includes a preheating mechanism, which includes a heating wire 23 wound around the inner wall of the sleeve 20. The heating wire 23 is used to preheat the core material 21 and the weld in advance after power is applied.

[0081] In this embodiment, guide rails 2 are provided on both sides of the workbench 4, and a slider is provided at the lower end of the vertical beam, and the guide rails 2 and the slider are slidably matched.

[0082] The consumable friction stir welding device provided in this embodiment further includes a ball screw transmission mechanism, which includes a ball screw 3 rotatably connected to the workbench 4 and a screw nut arranged on the vertical beam.

[0083] The consumable friction stir welding device provided in this embodiment further includes a third driving unit, which is a driving motor. The driving motor is fixedly mounted on the workbench 4 , and the driving end of the driving motor is drivingly connected to one end of the ball screw 3 .

[0084] There are ball screw transmission mechanisms and guide rail mechanisms on both sides of the workbench 4, which can control the horizontal feeding direction and distance of the core material.

[0085] The consumable friction stir welding device provided in this embodiment also includes a clamping block 12, a limit block 14 and a stop block 19 relatively arranged on the workbench 4, the limit block 14 and the stop block 19 are used to position the workpiece 16 to be welded; the clamping block 12 is arranged on the workbench 4 with adjustable height by bolts, and is used to clamp the workpiece 16 to be welded.

[0086] In this embodiment, there are two limit blocks 14 and two stop blocks 19 ; wherein, the two limit blocks 14 are located on one side of the workpiece 16 to be welded, and the two stop blocks 19 are located on the other side of the workpiece 16 to be welded.

[0087] The limiting block 14 is preferably triangular, and the blocking block 19 is preferably L-shaped.

[0088] In this embodiment, there are two pressing blocks 12 , which are respectively located on the other two sides of the workpiece 16 to be welded.

[0089] The consumable friction stir welding device provided in this embodiment further includes a discharge mechanism 22. The discharge mechanism 22 is located on one side of the workbench 4 and is used to place the welded parts for cooling.

[0090] Among them, the unloading mechanism 22 is a workpiece placement platform in the prior art, which will not be described in detail here.

[0091] Example 4

[0092] A welding method of a consumable friction stir welding device, using the consumable friction stir welding device provided in Example 1, Example 2, or Example 3 for welding, the welding method comprising the following steps:

[0093] S10. Place the workpiece to be welded on the workbench and fix it with a limit block, a pressing block and a blocking block;

[0094] S20, starting the hydraulic telescopic rod to push the movable beam downward, so that the second end of the sleeve and the core material extends into the groove of the weld;

[0095] S30, pressing the roller at the top of the flattening and protection mechanism against the surface of the workpiece to be welded under the action of a spring;

[0096] S40, energize the heating wire in the sleeve to start preheating the core material and the weld;

[0097] S50, after preheating is completed, the air hole is opened, and the motor is turned on to start the core material rotating;

[0098] S60, the pressure applying part applies pressure to the first end of the core material, and after the second end of the core material contacts the surface of the workpiece to be welded, friction between them generates heat;

[0099] S70, when the second end of the core material is gradually consumed due to friction (i.e., when the portion of the second end of the core material protruding from the sleeve is completely consumed), and the second end of the sleeve abuts against the surface of the weldment, the gantry is moved at a feed speed of 10 to 500 mm / min;

[0100] S80, blow out shielding gas from the blowing hole to protect the weld, and the roller flattens the weld to ensure the quality of the weld;

[0101] S90, open the pressing block and place the weldment on the unloading mechanism for cooling;

[0102] S100, return the mobile gantry to the initial position and reload the material to start the next round of welding task.

[0103] The above fully describes the technical solution of the present invention. It should be noted that the specific implementation of the present invention is not limited to the above description. All technical solutions formed by ordinary technicians in this field using equivalent or equivalent transformations in structure, method or function based on the spirit of the present invention fall within the scope of protection of the present invention.

Claims

1. A consumable friction stir welding device, characterized in that: include: Workbench, used to place parts to be welded; A mobile gantry, comprising two oppositely disposed vertical beams and a crossbeam fixedly connected between the two vertical beams; The vertical beam is slidably connected to the upper end of the workbench; a movable beam located in the movable gantry and capable of sliding relative to the movable gantry in a vertical direction; A first driving part, used for driving the movable beam to slide relative to the movable gantry; a hollow sleeve, wherein a first end of the sleeve is fixedly connected to the movable beam, and a second end of the sleeve is a free end, and the free end is located on a side of the movable beam away from the crossbeam; a hollow shaft rotatably connected to the sleeve, wherein a first end of the hollow shaft is located in the hollow cavity of the sleeve, and a second end of the hollow shaft passes through the moving beam and extends outside the moving beam; A core material, wherein the core material passes through the central hole of the hollow shaft, a first end of the core material extends to the outside of the hollow shaft and is located between the cross beam and the moving beam; a second end of the core material extends to the outside of the sleeve and contacts the workpiece to be welded; A second driving part is used to drive the hollow shaft to rotate along its central axis, thereby driving the core material to rotate; a pressure-applying portion, the pressure-applying portion being disposed on the movable gantry and configured to apply pressure to the first end of the core material to ensure that the second end of the core material is always in contact with the workpiece to be welded; The flattening and protection mechanism includes: a first flattening rod and a second flattening rod, wherein the first flattening rod is a hollow structure, a first end of the first flattening rod is connected to the moving beam via a first flange, a first end of the second flattening rod is at least partially slidably inserted into the first flattening rod, and a second end of the second flattening rod is provided with a flange near an end position; A spring is provided between the flange and the second end surface of the first flattening rod, a square frame is provided at the second end of the second flattening rod, and a roller is rotatably connected to the side of the square frame away from the second flattening rod; a blowing hole is provided between the second end of the second flattening rod and the flange, and the outlet direction of the blowing hole is directed to the welded seam so as to protect the welded seam with shielding gas; It also includes a clamping block, a limit block and a stop block relatively arranged on the workbench, the limit block and the stop block are used to position the parts to be welded; the clamping block is arranged on the workbench in an adjustable height by bolts, and is used to clamp the parts to be welded.

2. The consumable friction stir welding device according to claim 1, characterized in that: It also includes a preheating mechanism, which includes a heating wire wound around the inner wall of the sleeve, and the heating wire is used to preheat the core material in advance after power is applied.

3. The consumable friction stir welding device according to claim 1, characterized in that: Guide rails are provided on both sides of the workbench, and a slide block is provided at the lower end of the vertical beam. The guide rails and the slide block are slidably matched.

4. The consumable friction stir welding device according to claim 3, characterized in that: It also includes a ball screw transmission mechanism, which includes a ball screw rotatably connected to the workbench and a screw nut arranged on the vertical beam.

5. The consumable friction stir welding device according to claim 1, characterized in that: The first driving part is a hydraulic telescopic rod, the fixed end of the hydraulic telescopic rod is fixedly connected to the cross beam, and the driving end of the hydraulic telescopic rod is fixedly connected to the moving beam through a second flange.

6. The consumable friction stir welding device according to claim 1, characterized in that: The second driving part includes a motor arranged on the moving beam, a first gear arranged at the output end of the motor, a second gear is arranged at the first end of the hollow shaft, and the first gear is meshed with the second gear.

7. The consumable friction stir welding device according to claim 1, characterized in that: It also includes a unloading mechanism, which is located on one side of the workbench and is used to place the welded parts for cooling.

8. A welding method using the consumable friction stir welding device according to any one of claims 1 to 7, characterized in that: The following steps are involved: S10. Place the workpiece to be welded on the workbench and fix it with a limit block, a pressing block and a blocking block; S20, starting the hydraulic telescopic rod to push the movable beam downward, so that the second end of the sleeve and the core material extends into the groove of the weld; S30, pressing the roller at the top of the flattening and protection mechanism against the surface of the workpiece to be welded under the action of a spring; S40, energize the heating wire in the sleeve to start preheating the core material and the weld; S50, after preheating is completed, the air hole is opened, and the motor is turned on to start the core material rotating; S60, the pressure applying part applies pressure to the first end of the core material, and after the second end of the core material contacts the surface of the workpiece to be welded, friction between them generates heat; S70, when the portion of the second end of the core material that is higher than the sleeve is gradually worn away due to friction, and the second end of the sleeve abuts against the surface of the weldment, moving the gantry at a preset feed speed; S80, blow out shielding gas from the blowing hole to protect the weld, and the roller flattens the weld to ensure the quality of the weld; S90, open the pressing block and place the weldment on the unloading mechanism for cooling; S100, return the mobile gantry to the initial position and reload the material to start the next round of welding task.

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