A benchmarking-based method for equivalent transfer of inertia friction welding process parameters

Abstract

The application provides a benchmarking calibration piece-based inertia friction welding process parameter equivalent transplantation method, and belongs to the technical field of friction welding.The technical problem of the prior art that cross-device parameter transplantation relies on complex theoretical calculation, model error is high, and direct use of expensive target workpieces for "trial and error" results in extremely high test cost is solved.It comprises the following steps: on a source device, using a target workpiece to perform inertia friction welding process debugging, obtaining and locking an optimal process parameter combination meeting welding quality of the target workpiece; keeping the process parameter combination locked in step 1 unchanged, using a benchmarking calibration piece to perform welding on the source device; on a target device, setting a theoretically converted spindle initial rotating speed, and welding a benchmarking calibration piece with the same structure as that in step 2; repeating step 4 until the absolute value of the difference between the axial shortening amount of the benchmarking calibration piece on the target device and the benchmarking shortening amount is within 0.5 mm.It is mainly used for inertia friction welding of benchmarking calibration pieces.

Description

Technical Field

[0001] This invention belongs to the field of friction welding technology, and in particular relates to an equivalent transfer method of inertial friction welding process parameters based on a reference calibration component. Background Technology

[0002] Inertial friction welding is an advanced welding process that utilizes the rotational kinetic energy stored in an inertial disk (flywheel) to convert it into frictional heat energy, thereby achieving a solid-state connection of workpieces under axial pressure. Due to its significant advantages such as high weld joint strength, narrow heat-affected zone, and minimal deformation, this process is widely used in the manufacturing of high-temperature alloys and other difficult-to-weld metals in high-end equipment manufacturing fields such as aero-engines and gas turbines.

[0003] In actual production and process development, a mature inertial friction welding process often requires parameter transfer and replication between different models or batches of inertial friction welding machines. However, there are significant individual differences in the energy input capabilities between different inertial friction welding machines. These differences mainly stem from non-welding energy losses during equipment operation, such as mechanical friction losses of the spindle bearings, wind resistance losses during high-speed flywheel rotation, and internal leakage and response lag of the hydraulic system during upsetting.

[0004] Currently, conventional cross-device parameter porting methods in the industry mainly face the following technical bottlenecks: First, to compensate for the individual differences in the aforementioned equipment, existing parameter transfer methods often rely on establishing theoretical calculation models of equipment energy losses. However, because the internal mechanical losses and hydraulic dynamic losses of the equipment are extremely difficult to quantify accurately, the theoretical conversion has a high calculation error and cannot directly guide actual production.

[0005] Secondly, in order to correct errors in theoretical calculations, on-site engineers usually have to resort to a "trial and error" approach, which involves repeatedly testing and adjusting parameters on the target equipment using actual target workpieces. For high-end components such as thin-walled high-temperature alloys used in aero-engines, this method not only significantly extends the process debugging cycle, but also results in extremely high material waste and testing costs due to the extremely expensive materials used in the target workpieces. Summary of the Invention

[0006] In view of this, the present invention aims to propose an equivalent transfer method for inertial friction welding process parameters based on a reference calibration component, in order to solve the technical problems in the prior art where cross-equipment parameter transfer relies on complex theoretical calculations, has high model errors, and directly uses expensive target workpieces for "trial and error" resulting in extremely high experimental costs.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: an equivalent transfer method for inertial friction welding process parameters based on a reference calibration component, comprising the following steps: Step 1: On the source equipment, use the target workpiece to perform inertial friction welding process debugging, obtain and lock the optimal combination of process parameters that meets the welding quality of the target workpiece; Step 2: Keep the process parameter combination locked in Step 1 unchanged, use the reference calibration part for welding on the source equipment, and record the axial shortening of the reference calibration part after welding as the reference shortening amount. The centerline diameter of the weld joint of the reference calibration part is consistent with the centerline diameter of the weld joint of the target workpiece. Step 3: On the target equipment for which the parameters are to be transferred, set the upsetting pressure to the same value as in Step 1, and adjust the moment of inertia of the target equipment to a fixed value equal to or close to that of the source equipment. Step 4: On the target equipment, set the theoretically calculated initial spindle speed, weld the reference calibration part with the same structure as in Step 2, measure and record its axial shortening, and adjust the initial spindle speed of the target equipment as a single adjustment variable; Step 5: Repeat step 4 until the absolute value of the difference between the axial shortening of the reference calibration part on the target equipment and the reference shortening is within 0.5mm. At this time, lock the initial spindle speed of the target equipment, and use the initial spindle speed, the selected moment of inertia and the upsetting pressure as formal process parameters for formal welding of the target workpiece on the target equipment.

[0008] Furthermore, the target workpiece is made of high-temperature alloys used in aero-engine manufacturing or other high-cost, difficult-to-weld metal materials.

[0009] Furthermore, the reference calibration component is made of carbon steel or medium-high alloy steel, and its material cost is significantly lower than that of the target workpiece.

[0010] Furthermore, in order to compensate for the difference in material deformation resistance between the reference calibration part and the target workpiece at high temperature, the weld wall thickness of the reference calibration part is greater than that of the target workpiece, so that the two have equivalent plastic deformation resistance under the same upsetting pressure.

[0011] Furthermore, during the iterative calibration process in step 4, the initial spindle speed of the target device is adjusted by either a unidirectional gradient increase or a unidirectional gradient decrease.

[0012] Furthermore, the optimal combination of process parameters mentioned in step 1 includes the initial spindle speed, moment of inertia, and upsetting pressure of the source equipment.

[0013] Furthermore, in step 4, if the currently measured axial shortening is less than the reference shortening, the initial spindle speed of the target equipment is increased and the test welding is repeated; if the currently measured axial shortening is greater than the reference shortening, the initial spindle speed of the target equipment is decreased and the test welding is repeated.

[0014] Furthermore, in step 4, the initial spindle speed of the target device is adjusted by either a unidirectional gradient increase or a unidirectional gradient decrease.

[0015] Furthermore, in step 2, when welding the reference calibration component on the source device, the spindle speed decay curve is also recorded simultaneously as a reference curve.

[0016] Furthermore, in step 5, when the absolute value of the difference in axial shortening reaches within 0.5 mm, the fitting degree of the spindle speed decay curve on the target device with the reference curve is further compared to help verify the consistency of energy input.

[0017] Compared with the prior art, the beneficial effects of the present invention are: 1. This invention utilizes physical calibration components as an "energy scale," completely avoiding the differences in kinetic energy loss that are difficult to quantify and calculate between different friction welding machines (such as bearing friction, hydraulic internal leakage, etc.), avoiding the high errors caused by traditional theoretical energy conversion, and achieving precise physical-level replication of process parameters.

[0018] 2. For expensive and difficult-to-weld materials used in aero-engine manufacturing, this invention employs inexpensive carbon steel or medium-to-high alloy steel as substitutes for cross-equipment debugging. This method effectively avoids the scrapping and loss of valuable materials in the early stages of process transfer, resulting in significant economic benefits.

[0019] 3. This invention proposes a geometric design that increases the wall thickness of the calibration component to compensate for the difference in deformation resistance between inexpensive materials and high-end target materials. This design enables energy alignment testing to be performed with high fidelity under real stress conditions, ensuring the rigor and effectiveness of process transfer.

[0020] 4. This invention adopts a calibration logic of "constant upsetting pressure, constant moment of inertia + single-variable closed-loop adjustment of spindle speed," and uses "axial shortening error ≤ 0.5mm" as an objective quantitative criterion. This solution greatly simplifies the operation difficulty for on-site engineers, eliminates excessive reliance on operator experience, and significantly shortens the parameter introduction cycle for new equipment. Attached Figure Description

[0021] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings: Figure 1 A cross-sectional view comparing the weld structure of the target workpiece and the reference calibration part; Figure 2 A flowchart illustrating the process of iteratively transferring and replicating process parameters on the target equipment; Figure 3 This is a comparison chart showing the fitting of the spindle speed decay curve of the reference calibration component after cross-equipment calibration. Detailed Implementation

[0022] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. It should be noted that, unless otherwise specified, the embodiments and features in the embodiments of the present invention can be combined with each other, and the described embodiments are only some embodiments of the present invention, not all embodiments.

[0023] Detailed Implementation Method 1: See Figure 1-3 This embodiment describes a method for equivalent transfer of inertial friction welding process parameters based on a reference calibration component. In actual production, the optimal welding process parameters for this thin-walled high-temperature alloy ring have been successfully developed and solidified on the source equipment (equipment A). Now, it is necessary to equivalently transfer this process to a new equipment (equipment B) with unknown energy loss characteristics. This embodiment uses the following specific steps to replicate the parameters: Step 1: Source device (A device) parameter locking and reference workpiece design: First, obtain the optimal combination of process parameters for successfully welding a thin-walled high-temperature alloy ring (target workpiece) on equipment A: upsetting pressure P, initial spindle speed nA, and flywheel moment of inertia IA.

[0024] Subsequently, a carbon steel reference calibration component for energy calibration was designed and manufactured. To compensate for the difference in plastic deformation capacity between carbon steel and high-temperature alloys, the centerline diameter of the weld joint of the reference calibration component was strictly kept consistent with that of the target workpiece, but the weld joint wall thickness of the reference calibration component was appropriately increased. This ensured that the overall plastic deformation resistance of the carbon steel reference calibration component under the preset upsetting pressure P reached an equivalent level to that of the thin-walled high-temperature alloy target workpiece.

[0025] The second step is the benchmark calibration test of the source device (device A): On equipment A, keeping the aforementioned optimal process parameters (P, nA, IA) completely unchanged, the target workpiece is replaced with a carbon steel reference calibration part for trial welding. After welding, the axial shortening ΔLA of the carbon steel reference calibration part is accurately measured and recorded. Simultaneously, the spindle speed decay curve is recorded. The measured ΔLA serves as the physical reference scale for subsequent replication.

[0026] Step 3, setting variables for the target device (Device B): In the control system of equipment B, the upsetting pressure is set to the exact same value P as that of equipment A. By increasing or decreasing the counterweight of the flywheel of equipment B, its moment of inertia IB is adjusted to be as close as possible to a fixed value equal to that of equipment A (or the closest value is taken and kept constant).

[0027] Step 4: Iterative parameter adjustment of the target device (device B): Initial test welding: Set an initial rotational speed nB0 for device B based on theoretical energy conversion, weld a carbon steel reference calibration part of the same size on device B, and measure the axial shortening ΔLB0.

[0028] Deviation judgment and unidirectional fine adjustment: Compare ΔLB0 with the reference ΔLA of device A.

[0029] If ΔLB0 is less than (ΔLA - 0.5mm), it indicates that equipment B has greater energy loss. Therefore, the initial spindle speed of equipment B should be increased for the next test weld. If ΔLB0 is greater than (ΔLA + 0.5mm), it indicates that the energy loss of equipment B is relatively small. Therefore, the initial spindle speed of equipment B should be reduced for the next test weld.

[0030] The entire process uses the spindle speed as the sole adjustment variable for unidirectional gradient adjustment.

[0031] Step 5, Parameter Locking and Official Reissue: After multiple iterations, the axial shortening ΔLBn of the carbon steel reference calibration part welded on equipment B met the following condition: absolute value |ΔLBn - ΔLA| ≤ 0.5mm.

[0032] The specific embodiments of the present invention disclosed above are merely illustrative of the invention. These embodiments do not exhaustively describe all details, nor do they limit the invention to the specific embodiments described. Many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention.

Claims

1. A method for equivalent transfer of inertial friction welding process parameters based on a reference calibration component, characterized in that: It includes the following steps: Step 1: On the source equipment, use the target workpiece to perform inertial friction welding process debugging, obtain and lock the optimal combination of process parameters that meets the welding quality of the target workpiece; Step 2: Keep the process parameter combination locked in Step 1 unchanged, use the reference calibration part for welding on the source equipment, and record the axial shortening of the reference calibration part after welding as the reference shortening amount. The centerline diameter of the weld joint of the reference calibration part is consistent with the centerline diameter of the weld joint of the target workpiece. Step 3: On the target equipment for which the parameters are to be transferred, set the upsetting pressure to the same value as in Step 1, and adjust the moment of inertia of the target equipment to a fixed value equal to or close to that of the source equipment. Step 4: On the target equipment, set the theoretically calculated initial spindle speed, weld the reference calibration part with the same structure as in Step 2, measure and record its axial shortening, and adjust the initial spindle speed of the target equipment as a single adjustment variable; Step 5: Repeat step 4 until the absolute value of the difference between the axial shortening of the reference calibration part on the target equipment and the reference shortening is within 0.5mm. At this time, lock the initial spindle speed of the target equipment, and use the initial spindle speed, the selected moment of inertia and the upsetting pressure as formal process parameters for formal welding of the target workpiece on the target equipment.

2. The method for equivalent transfer of inertial friction welding process parameters based on a reference calibration component according to claim 1, characterized in that: The target workpiece is made of a high-temperature alloy used in aero-engine manufacturing.

3. The method for equivalent transfer of inertial friction welding process parameters based on a reference calibration component according to claim 1, characterized in that: The reference calibration component is made of carbon steel or medium-high alloy steel.

4. The method for equivalent transfer of inertial friction welding process parameters based on a reference calibration component according to claim 1, characterized in that: The weld wall thickness of the reference calibration component is greater than the weld wall thickness of the target workpiece.

5. The method for equivalent transfer of inertial friction welding process parameters based on a reference calibration component according to claim 1, characterized in that: The optimal combination of process parameters mentioned in step 1 includes the initial spindle speed, moment of inertia, and upsetting pressure of the source equipment.

6. The method for equivalent transfer of inertial friction welding process parameters based on a reference calibration component according to claim 1, characterized in that: If the measured axial shortening in step 4 is less than the reference shortening, the initial spindle speed of the target equipment is increased and the test welding is repeated. If the measured axial shortening is greater than the reference shortening, the initial spindle speed of the target equipment is decreased and the test welding is repeated.

7. The method for equivalent transfer of inertial friction welding process parameters based on a reference calibration component according to claim 1, characterized in that: In step 4, the initial spindle speed of the target device is adjusted by either increasing or decreasing in a unidirectional gradient.

8. The method for equivalent transfer of inertial friction welding process parameters based on a reference calibration component according to claim 1, characterized in that: In step 2, when welding the reference calibration component on the source device, the spindle speed decay curve is also recorded simultaneously as a reference curve.

9. The method for equivalent transfer of inertial friction welding process parameters based on a reference calibration component according to claim 8, characterized in that: In step 5, when the absolute value of the difference in axial shortening reaches within 0.5 mm, the fitting degree of the spindle speed decay curve on the target equipment with the reference curve is further compared to help verify the consistency of energy input.

Images