Adjustable Shoulder Structure for Variable-Angle Fillet Stir Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing friction stir welding tools are limited to welding fillet joints with constant angles, requiring costly and time-consuming redesigns for non-standard angles, increasing manufacturing costs and processing complexity.
Innovation Solution
A shoulder-angle-adjustable friction stir welding tool with a movable shoulder and adjustable stirring pin channel, allowing the stirring pin to pass through, featuring a rotating joint, angle adjusting plate, and limiting adjustment bolts to accommodate various fillet joint angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the friction stir welding tool is designed for a constant angle fillet joint, then the welding quality is stable, but the tool cannot weld fillet joints with nonstandard angles, reducing adaptability
Solution Approach 1:
The shoulder is designed as a movable component that can rotate around the stirring pin channel, changing from a fixed structure to a dynamic one. This allows the shoulder angle to be adjusted according to different fillet joint angles while maintaining stable welding quality through proper angle positioning
Solution Approach 2:
The angle between the shoulder and the stirring pin channel can be changed by rotating the shoulder, allowing the tool to adapt to different fillet joint angles. This parameter change enables the same tool to maintain optimal welding conditions for various angle requirements
2Adaptability or versatility
If the friction stir welding tool is redesigned to weld nonstandard angle fillet joints, then the adaptability is improved, but the redesign is time-consuming and effort-consuming, increasing manufacturing cost
Solution Approach 1:
Instead of creating multiple fixed-angle tools, a single tool with a movable shoulder is designed. The shoulder can be rotated and positioned to match different fillet joint angles, eliminating the need for costly and time-consuming redesigns for each angle requirement
Solution Approach 2:
The friction stir welding tool is designed to perform multiple functions by accommodating different fillet joint angles through the movable shoulder mechanism. This universal design allows one tool to replace multiple specialized tools, reducing manufacturing costs and complexity
3Device complexity
If the fillet joint is converted into a butt joint for welding, then the welding process is simplified, but the manufacturing and processing cost increases due to additional transition sections and inclined planes
Solution Approach 1:
The movable shoulder allows the welding tool to directly weld fillet joints at various angles without requiring conversion to butt joints. This maintains the original fillet joint structure, avoiding the need for additional transition sections and inclined planes that会增加 manufacturing and processing costs
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient welding of fillet joints with different angles, expanding the tool's application scope by allowing for precise angle adjustments, reducing manufacturing costs, and improving welding quality by maintaining consistent heat and material flow.
Implementation Method 1
a stirring tool rubs against a welded material to generate heat
Implementation Method 2
the first shoulder is rotationally connected with the second shoulder
Data Source
AI summary
A shoulder-angle-adjustable friction stir welding head suitable for a fillet joint includes a stirring head body. A front end of the stirring head body is mounted with a movable shoulder, a stirring pin channel is arranged on the movable shoulder, and the stirring pin channel may allow a stirring pin of the stirring head body to pass through. The present disclosure can respond to welding tasks of the fillet joint of different angles and enlarges an application scope of the friction stir welding head in a manner that the front end of the stirring head body is mounted with the movable shoulder, the stirring pin channel is arranged on the movable shoulder, the stirring pin channel is used for allowing the stirring pin of the stirring head body to pass through, and the angle of the movable shoulder is adjusted.