Friction Stir Welding of Side Surfaces With Biaxial Tool Orientation
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Solution Overview
Problem
Existing friction stir welding devices face complexity in controlling the direction and movement of L-shaped attachments for welding side surfaces with polygonal or curved contours, requiring intricate coordination of X-axis and C-axis rotations.
Innovation Solution
A friction stir welding device with a rotatable table and L-shaped tool holder, controlled by a biaxial operation mode, allows the welding tool to be directed normally to the side surface by rotating the table and tool holder, simplifying the operation and enabling easy welding of complex contours.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an L-shaped attachment is used to perform friction stir welding of a side surface of a workpiece, then it is possible to weld side surfaces, but the control becomes complicated when the workpiece has a polygonal or curved contour
Solution Approach 1:
Instead of moving and orienting the L-shaped attachment along the workpiece contour, the invention inverts the approach by rotating the workpiece on a rotatable table to bring different portions of the contour to a fixed welding position. This simplifies control by eliminating the need for complex coordinated movement of the attachment along curved or polygonal paths.
Solution Approach 2:
The invention introduces a new degree of freedom by adding a rotatable table that rotates the workpiece about a vertical axis. This dimensional change allows the welding tool to remain stationary while the workpiece presents different surfaces to the tool, simplifying the control architecture compared to moving the tool along complex 2D contours.
2Productivity
If the L-shaped attachment is moved along the side surface of a workpiece with polygonal or curved contour, then welding can be performed, but cooperative control of X-axis and Y-axis is required which makes control complicated
Solution Approach 1:
The invention inverts the traditional welding approach by keeping the welding tool stationary and rotating the workpiece on a table to bring different portions to the welding position. This eliminates the need for complex cooperative control of X and Y axes along contours, simplifying operation while maintaining welding productivity.
Solution Approach 2:
The invention separates the functions of positioning and welding by using a rotatable table to handle workpiece positioning while the welding tool remains fixed. This segmentation of functions simplifies control by eliminating the need for coordinated multi-axis movement of the welding tool itself.
3Manufacturing precision
If the welding tool is constantly directed in the normal direction with respect to the side surface, then proper welding is achieved, but the direction of the L-shaped attachment must be adjusted by rotating the main shaft
Solution Approach 1:
Instead of actively adjusting the L-shaped attachment to maintain normal direction, the invention inverts the approach by rotating the workpiece on a table so that the surface to be welded is always presented in the correct orientation to the fixed welding tool. This eliminates the need for complex orientation control of the attachment.
Solution Approach 2:
The workpiece effectively orients itself by rotating on the table, presenting the correct surface to the welding tool at each position. This self-service approach eliminates the need for active orientation control mechanisms in the attachment, simplifying the device while maintaining welding precision.
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 friction stir welding on side surfaces with polygonal or curved contours by maintaining the welding tool's direction orthogonal to the surface, simplifying control and operation.
Implementation Method 1
a welding tool that is supported by the tool holder and that is configured to rotate about a tool rotation axis intersecting the holder rotation axis
Implementation Method 2
a table that has a placement surface on which a workpiece is to be placed and that is rotatable about a table rotation axis intersecting the placement surface
Implementation Method 3
a tool holder that is movable relative to the table in a direction along the placement surface and that is rotatable about a holder rotation axis parallel to the table rotation axis
Data Source
AI summary
A friction stir welding device includes a table that has a placement surface on which a workpiece is to be placed and is rotatable about a table rotation axis intersecting the placement surface, a tool holder movable relative to the table in a direction along the placement surface and rotatable about a holder rotation axis parallel to the table rotation axis, and a welding tool supported by the tool holder and rotating about a tool rotation axis intersecting the holder rotation axis. A control device has a biaxial operation mode in which the welding tool in a rotating state is pressed against a welding portion of a side surface of the workpiece, the welding tool is relatively moved along the welding portion by rotating the table, and the tool holder is rotated so that the welding tool is directed in a normal direction of the welding portion.