Friction Stir Welding Positioning With Surface-Protective Holding
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Solution Overview
Problem
Friction stir welding faces challenges in maintaining precise positioning and preventing surface damage during the joining of overlaid members, particularly when using tools with small diameters, as existing methods struggle to accurately determine the offset distance between imaging units and tools, and apply sufficient pressure without causing deformation or damage.
Innovation Solution
The friction stir welding equipment incorporates a spindle unit, holder, and moving parts to rotate and position the tool relative to the processing member, using a pressing mechanism with multiple claws to secure the member and an imaging system to determine the offset distance between the imaging unit and tool, allowing for precise positioning and measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the force that presses onto the upper surface of the member on the upper side is increased to prevent positional shifts, then positioning stability is improved, but there is a risk that damage to the upper surface of the member may occur
Solution Approach 1:
A pressing member is introduced as an intermediary component between the pressing force and the upper surface of the member to be joined. This pressing member applies the necessary pressing force to prevent rotational shifting while protecting the upper surface from direct contact with the tool, thus avoiding surface damage. The pressing member acts as a mediator that distributes and controls the application of force.
2Manufacturing precision
If a tool with a small diameter is used to improve joining quality, then manufacturing precision is improved, but it becomes more difficult to accurately determine the offset distance between the imaging unit and tool
Solution Approach 1:
A mark member with a mark is positioned at a known offset distance from the tool to serve as a reference for the imaging unit. Instead of directly measuring the offset to the small-diameter tool, the system captures an image of the mark and calculates the offset based on the known relationship between the mark and tool positions. This indirect measurement approach maintains precision while accommodating small tool diameters.
3Productivity
If the tool rotates at high speed to improve welding efficiency, then productivity is improved, but the rotational force may cause the member to shift or deform
Solution Approach 1:
The pressing member applies a pressing force to the upper surface of the member before the tool makes contact and begins rotating. This preliminary action counteracts the rotational force that will be generated during welding, preventing the member from shifting or deforming. By applying the counteracting force in advance, the system maintains member stability even at high rotation speeds.
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 solution enhances the accuracy and quality of friction stir welding by preventing positional shifts and surface damage, enabling efficient measurement of tool shoulder distance and improving productivity by eliminating the need for consumable parts and extending tool life.
Implementation Method 1
plastic flow of the material of a member (a main material) to be joined is caused by the pressure and the angular moment of a rotating tool
Implementation Method 2
Friction stir welding (FSW; Friction Stir Welding), plastic flow of the material of a member (a main material) to be joined is caused by the pressure and the angular moment of a rotating tool
Data Source
AI summary
A friction stir welding equipment according to an embodiment includes a spindle unit, a holder, and a moving part; the spindle unit is capable of rotating a tool; the holder is connectable to the tool via a radial bearing and is capable of holding at least one of a side surface of a processing member or a rim of an upper surface of the processing member; and the moving part is capable of changing relative positions of the tool and the holder with respect to the processing member.