Linear Friction Welding Layout for Accurate Pressure Measurement
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Solution Overview
Problem
Conventional linear friction welding apparatuses face challenges in maintaining welding accuracy due to increased size of metal components, which leads to higher frictional forces, moment loads, and difficulties in accurately measuring pressure forces, resulting in reduced precision and efficiency.
Innovation Solution
The apparatus incorporates a pressure mechanism with a hydrostatic bearing and a support mechanism featuring a linear guide to distribute pressure forces effectively, reducing the load on load sensors and improving measurement accuracy, while the oscillation mechanism is positioned below the intersection of pressure and oscillation axes to minimize moment loads and enhance precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the size of metal components is increased, then the welded area increases, but the frictional force between weld joint surfaces increases, requiring larger clamp cylinders and reducing apparatus size reduction
Solution Approach 1:
A linear guide is introduced as an intermediary mechanism between the clamp cylinder and the oscillation jig base. The linear guide receives the thrust from the clamp cylinder and transmits it to the oscillation jig base, effectively mediating the force transmission. This allows the use of a smaller clamp cylinder while maintaining the necessary clamping force on large components.
Solution Approach 2:
The force transmission path is segmented into distinct functional components: the clamp cylinder generates thrust, the linear guide transmits and guides this force, and the oscillation jig base applies the clamping force. This segmentation allows each component to be optimized independently, enabling apparatus size reduction while handling large components.
2Force
If the thrust of clamp cylinder is increased to enhance holding force, then the clamping force increases, but the size of clamp cylinder and related components increases
Solution Approach 1:
The linear guide acts as a force-multiplying intermediary that allows a smaller clamp cylinder to generate sufficient clamping force through efficient force transmission and guidance, preventing energy loss and enabling apparatus size reduction.
Solution Approach 2:
The clamp cylinder utilizes hydraulic or pneumatic principles to generate high thrust density, allowing compact sizing while maintaining the required clamping force for large metal components during welding.
3Measurement precision
If load sensor is used to measure pressure force, then pressure control is enabled, but moment loads and downward loads reduce measurement accuracy
Solution Approach 1:
The measurement function is extracted and isolated to a dedicated load sensor positioned at the oscillation axis intersection. This separate measurement point eliminates the interference of moment loads from the pressure force measurement, allowing accurate simultaneous measurement of both parameters.
Solution Approach 2:
The load sensor serves as an intermediary measurement device that indirectly measures pressure force through the oscillation axis intersection point, where moment loads do not interfere with the measurement, thus mediating between the complex force system and the measurement requirement.
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 configuration enables higher accuracy in welding large metal components by accurately measuring pressure forces and reducing moment loads, leading to improved precision and efficiency in integrating blades and disks within blisks.
Implementation Method 1
The apparatus incorporates a pressure mechanism with a hydrostatic bearing
Implementation Method 2
The apparatus incorporates a pressure mechanism with a hydrostatic bearing and a support mechanism featuring a linear guide
Implementation Method 3
Linear friction welding apparatus for welding weld joint surfaces of a pair of metal components, such as a blade and a disk of a blisk (a bladed disk), by use of a frictional heat generated between the weld joint surfaces of the pair of the metal components
Data Source
AI summary
A linear friction welding apparatus for welding a first member and a second member together by friction welding by pressing the first member and the second member against each other while causing a relative oscillation movement between the first member and the second member, the apparatus comprising: an oscillation mechanism having an oscillation axis in a direction perpendicular to the pressure axis of the pressure mechanism and configured to oscillate the first member or the second member in the direction of the oscillation axis to cause the relative oscillation movement between the first member and the second member; a slider configured to hold the first holding member and movable in a vertical direction; a bearing mechanism configured to receive a pressure force acting on the slider in the direction conforming to the pressure axis; and a drop prevention mechanism configured to prevent the slider from dropping down when the slider does not hold the first holding member, wherein the oscillation mechanism includes an oscillation cylinder in contact with a bottom of the first holding member, and is located below an intersection between the pressure axis and the oscillation axis.