Internal Coolant Channel Layout for Friction Stir Tool Cooling
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Solution Overview
Problem
Existing friction stir welding methods face inefficiencies in cooling the friction stir tool, leading to increased wear, reduced service life, and compromised mechanical properties of the weld zone, especially during long-distance or large-thickness plate welding.
Innovation Solution
A friction stir tool cooling method that introduces a coolant into a cooling channel inside the tool, utilizing forced convection to efficiently cool the stirring pin and/or shaft shoulder, with the coolant flowing downward to surround the tool components and then flowing upward for exit, thereby directly reaching and cooling the tool's end.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If surface cooling methods are used to cool friction stir tools, then the cooling process is simple to implement, but the cooling efficiency is low because the heat is transferred to the position of the shaft shoulder and stirring pin before cooling occurs
Solution Approach 1:
A coolant is introduced as an intermediary substance through a cooling channel that directly contacts the stirring pin and shaft shoulder. The coolant absorbs heat directly from these components through convection and conduction, eliminating the need for heat transfer to distant surfaces before cooling. This intermediary approach enables efficient direct cooling while maintaining simple implementation.
Solution Approach 2:
The cooling approach transitions from surface cooling (two-dimensional external cooling) to internal cooling through a cooling channel (three-dimensional internal cooling). The cooling channel is positioned inside the friction stir tool, allowing coolant to flow directly around the stirring pin and shaft shoulder in the internal dimension, achieving superior cooling efficiency while keeping the external structure simple.
2Temperature
If the rotation speed is reduced and traverse speed is increased to reduce friction stir tool temperature, then the tool temperature decreases, but the welding process becomes slower and less efficient
Solution Approach 1:
The temperature control function is extracted from the welding process parameters (rotation speed and traverse speed) and placed into a separate cooling system. The cooling channel with coolant flow independently manages tool temperature, allowing the welding parameters to be optimized for high productivity without being constrained by temperature control requirements.
Solution Approach 2:
Cooling action is applied preliminarily and continuously to the friction stir tool before and during the welding process. The coolant flows through the cooling channel in advance, pre-cooling the tool components, and maintains continuous cooling during welding. This preliminary and ongoing cooling enables high-speed welding without excessive temperature rise.
3Ease of manufacture
If cooling channels are positioned far from the stirring pin and shaft shoulder, then the cooling system is easier to manufacture, but the cooling effectiveness at the critical components is reduced
Solution Approach 1:
The cooling channel is nested inside the friction stir tool structure, with the channel positioned concentrically or adjacently to the stirring pin and shaft shoulder. This nested arrangement allows the cooling channel to be integrated into the tool during manufacturing, maintaining ease of fabrication while achieving close proximity between the coolant flow and the critical components that require cooling.
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 method effectively and promptly reduces the temperature of the friction stir tool, enhancing cooling efficiency, extending tool service life, and improving the quality and mechanical properties of the weld, especially during demanding welding processes.
Implementation Method 1
A friction stir tool cooling method for cooling the stirring pin and/or shaft shoulder of the friction stir tool... the coolant flows downward to the vicinity of the stirring pin and/or shaft shoulder
Data Source
AI summary
A friction stir tool cooling method is used for cooling a stirring pin and/or a shaft shoulder of a friction stir tool, it includes that the coolant is introduced into an inlet of a cooling channel, the cooling channel is provided inside the friction stir tool, and the inlet is provided on the side wall of the friction stir tool. The coolant flows downwards to the vicinity of the stirring pin and/or the shaft shoulder, the coolant turns upwards and flows out of the friction stir tool from an outlet. The outlet is provided on the side wall of the friction stir tool.