Friction Stir Welding Tool Structure to Block Chip Ingress
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Solution Overview
Problem
Friction stir welding apparatuses face issues with cutting chips, such as burrs, entering the gap between the probe and the shoulder, which affects the quality of the joint.
Innovation Solution
The apparatus includes a probe, a shoulder, and an annular member with recess parts and taper portions to block and guide cutting chips, ensuring they do not enter the gap between the probe and the shoulder, while also efficiently transmitting heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a clearance (gap) is formed between the probe and the shoulder, then the probe can be stably held by the shoulder, but cutting chips can enter the gap and affect joint quality
Solution Approach 1:
A blocking member is introduced as an intermediary element between the probe and shoulder. This blocking member fills the gap while allowing the probe to remain stable, and simultaneously prevents cutting chips from entering the gap. The blocking member acts as a mediator that resolves the contradiction by providing both structural support and contamination prevention.
Solution Approach 2:
The gap between the probe and shoulder is segmented into two functional zones: an upper zone that allows chip ejection and a lower zone blocked by the blocking member that prevents chip entry. This segmentation enables the system to maintain both probe stability and joint quality by dividing the gap's function into distinct regions.
2Productivity
If the probe is rotated at high speed to generate friction heat, then welding efficiency is improved, but heat retention in the probe increases
Solution Approach 1:
Heat is extracted from the probe by allowing it to escape through the gap between the probe and shoulder. The gap serves as a thermal release pathway, extracting excess heat from the probe while maintaining the high rotation speed necessary for efficient welding. This extraction mechanism resolves the contradiction by providing a heat dissipation route without reducing welding productivity.
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
This configuration effectively prevents cutting chips from entering the gap, improving the quality of the joint and reducing heat retention in the probe, thereby enhancing the welding process.
Implementation Method 1
by rotating and moving a tool (hereinafter, referred to as a probe) on a joined member, the joined member is welded by friction heat generated between the probe and the joined member
Implementation Method 2
the outside part of the annular member protrudes from the recess part, and the gap between the probe and the shoulder can be blocked by the annular member
Implementation Method 3
by fitting the annular member to the recess part, heat transmitted to the probe at the time of the friction stir welding can be transmitted (escape) to the shoulder via the annular member
Data Source
AI summary
A friction stir welding apparatus includes a probe, a shoulder, a recess part, and an annular member. The probe is pressed to a joint part of a plurality of joined members while being rotated. The shoulder is formed so as to surround the probe at an outside in a radial direction with respect to a rotation axis of the probe. The recess part is formed on at least one of an outer circumference of the probe and an inner circumference of the shoulder. The annular member is fitted to the recess part.