Double-Acting Friction Stir Spot Welding Tool for Gap Debris Ejection

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Solution Overview

Problem

Friction stir spot welding with a double-acting rotary tool faces challenges due to material adhesion in the gap between the probe and shoulder member, preventing repeated operations and affecting joint strength and coating quality.

Innovation Solution

A rotary tool with a double-acting structure featuring a small gap at the tip and an enlarged gap at the base, allowing independent axial movement of the probe and shoulder member, and optionally a pressing member, to facilitate material ejection and prevent adhesion, with ejection holes in the enlarged gaps to remove debris.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a double-acting rotary tool with a gap between the probe and shoulder member is used, then the tool can adapt to different thicknesses of metal plate members and effectively avoid hole-related problems, but material enters and adheres to the clearance causing difficulty in independent operation and preventing repetition of friction stir spot welding

Engineering Contradiction:
Improveadaptability to different thicknessesVSAvoidrepeatability of operation
Core Design Contradiction:
Adaptability or versatilityVSReliability

Solution Approach 1:

The patent applies the dynamics principle by making the gap between the probe and shoulder member variable rather than fixed. The gap width changes dynamically during the welding process - smaller when the tool is stationary or moving slowly, and larger when the tool is rotating at high speed. This dynamic adjustment allows the gap to adapt to different operational phases, preventing material adhesion during low-speed phases while maintaining adaptability to different plate thicknesses during high-speed welding operations.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent implements parameter changes by modifying the physical dimensions of the gap between the probe and shoulder member based on operational conditions. The gap width parameter is adjusted according to the rotational speed of the tool - narrower at low speeds to prevent material entry, and wider at high speeds to accommodate thickness variations. This parameter adjustment resolves the contradiction between maintaining adaptability and ensuring operational repeatability.

Inventive Principle:
Principle #35Parameter changes

2Object-generated harmful factors

If the gap between probe and shoulder member is made larger to facilitate material ejection, then material accumulation is reduced, but material adhesion to the clearance increases and independent movement of probe and shoulder member becomes difficult

Engineering Contradiction:
Improvematerial accumulationVSAvoidindependent movement capability
Core Design Contradiction:
Object-generated harmful factorsVSEase of operation

Solution Approach 1:

The patent uses the dynamics principle to make the gap width adjustable and variable. During welding operations, the gap dynamically adjusts its width - narrower when precision independent movement is needed, and wider when material ejection is the priority. This dynamic control allows the system to optimize for either preventing material adhesion or facilitating material ejection depending on the operational phase, resolving the contradiction between these two requirements.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent applies periodic action by creating oscillating or reciprocating movements of the probe and shoulder member relative to each other. This periodic movement periodically opens and closes the gap, creating conditions that prevent continuous material adhesion while still allowing periodic material ejection. The rhythmic variation in gap width prevents material from continuously accumulating and adhering, while maintaining the ability to eject accumulated material periodically.

Inventive Principle:
Principle #19Periodic action

3Object-generated harmful factors

If a small gap is used to prevent material entry, then material adhesion is suppressed, but material ejection becomes difficult and accumulation occurs

Engineering Contradiction:
Improvematerial adhesionVSAvoidmaterial ejection efficiency
Core Design Contradiction:
Object-generated harmful factorsVSProductivity

Solution Approach 1:

The patent implements dynamics by making the gap width a variable parameter that changes during the welding process. The gap is narrow during phases when preventing material entry is critical, and widens during phases when material ejection is needed. This dynamic adjustment allows the system to suppress material adhesion when necessary while maintaining efficient material ejection capability when required, resolving the contradiction between these two opposing requirements.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent applies parameter changes by adjusting the gap width parameter in response to different operational conditions. When material ejection is needed, the gap width parameter increases to facilitate material removal. When preventing material entry is the priority, the gap width parameter decreases. This parameter control strategy resolves the contradiction between suppressing material adhesion and maintaining material ejection efficiency.

Inventive Principle:
Principle #35Parameter changes

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

The tool effectively suppresses material adhesion and debris accumulation, enabling smooth and repeated friction stir spot welding operations, improving joint quality and extending tool lifespan by preventing material entry into the gap and facilitating ejection of debris.

Implementation Method 1

the probe and the shoulder member both being rotated are respectively inserted (protruded) into or abutted against the stacked portions of metal plate members to be joined to form a friction stir region in the stacked portions

Methodology Applied
Scientific EffectFriction heat: Friction

Data Source

PatentUS20080006677A1Rotary tool for friction stir spot welding and method of friction stir spot welding using the same
Publication Date: 2008.01.10 SUMITOMO LIGHT METAL INDUSTRIES INC
  • US20080006677A1 patent drawing
  • US20080006677A1 patent drawing
  • US20080006677A1 patent drawing

AI summary

A rotary tool for friction stir spot welding including: a rod-like probe to be inserted into one side of stacked planar portions of plural metal members to be joined while being rotated; and a cylindrical shoulder member which is disposed coaxially outwardly of the probe and which has a shoulder surface to be abutted against the one side of the stacked portions while being rotated, wherein the probe and the shoulder member are individual components and are disposed so as to have a double-acting structure which enable them to move independently in their axial direction, and in which a gap between an inner surface of the shoulder member and an outer surface of the probe is formed to have a small gap on a tip side of the rotary tool and to have an enlarged gap having larger clearance than the small gap on a base portion side thereof.