Friction Welding with Same-Direction Rotation During Axis Alignment
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Solution Overview
Problem
Conventional friction welding methods require stopping the rotation of materials to align axes for pressure contacting, making it difficult to maintain the necessary state for friction welding.
Innovation Solution
A friction welding method where materials are moved from a state of axis misalignment to alignment while rotating at the same speed in the same direction for friction heating and pressure contacting, allowing continuous rotation during the heating and pressure contacting steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If materials are rotated in mutually opposite directions for friction heating, then friction welding can be carried out, but it is difficult to maintain the necessary state for friction welding when stopping rotation for pressure contacting
Solution Approach 1:
The patent inverts the conventional rotation direction arrangement. Instead of rotating materials in mutually opposite directions, both materials are rotated in the same direction at the same speed. This inversion allows the materials to maintain their rotational state during axis alignment and pressure contacting, eliminating the need to stop rotation and thereby maintaining the welding state reliably while improving productivity.
2Manufacturing precision
If materials are stopped for axis alignment, then pressure contacting can be achieved, but the state required for friction welding cannot be easily maintained
Solution Approach 1:
The patent applies preliminary action by performing axis alignment while the materials are still rotating. The control unit adjusts the rotational speeds of the spindles to achieve axis alignment before the pressure contacting step, so that the materials are already in the correct positional relationship when pressure is applied, eliminating the need to stop rotation and maintaining welding state reliability.
Solution Approach 2:
The patent employs dynamics by allowing continuous rotation during the entire welding process. The control unit dynamically adjusts the rotational speeds of the spindles to achieve axis alignment while rotating, and maintains rotational motion during pressure contacting. This dynamic approach ensures both precise axis alignment and reliable maintenance of the welding state without interruption.
3Strength
If rotation is stopped for pressure contacting, then joining can be achieved, but process efficiency is reduced due to interruption
Solution Approach 1:
The patent implements continuity of useful action by maintaining rotational motion throughout the entire friction welding process, including during the pressure contacting step. The control unit coordinates the rotational speeds of both spindles to ensure continuous rotation while achieving axis alignment and applying pressure. This eliminates interruptions and maintains process efficiency while still achieving strong joints through continuous friction heating and pressure application.
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 easy maintenance of the state required for friction welding, improving the efficiency and effectiveness of the process by maintaining temperature and alignment without stopping the rotation of the materials.
Implementation Method 1
the pair of materials are moved from a state in which their axes are unaligned with each other, in a direction for aligning the respective axes with each other, to a prescribed position where the joining surfaces are brought into contact with each other and friction heated
Data Source
Figure 1
Figure 2A~2C
Figure 3A~3D
AI summary
Disclosed is a friction welding method including: a heating step wherein, in relation to joining surfaces (S1, S2) defined by opposite end surfaces of a pair of materials (W1, W2) that are held by a respective pair of opposite spindles (3a, 3b), the pair of materials (W1, W2) are moved from a state in which their axes are unaligned with each other, in a direction for aligning the respective axes with each other, to a prescribed position where the joining surfaces (S1, S2) are brought into contact with each other and friction heated; and a pressure contacting step wherein the pair of materials are brought into pressure contact with each other at the prescribed position. The method is characterized in that the heating step and the pressure contacting step are carried out while rotating each of the materials (W1, W2) at the same rotation speed in the same direction, as seen from one side in the axial direction. Also disclosed is a machine tool (1) for implementing the friction welding method.