Friction Stir Welding Head Accessory for Weld Burr Removal
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Solution Overview
Problem
Friction stir welding heads generate residual roughness and burrs along the weld line, and existing technologies do not allow for automated addition of working tools, necessitating additional operations for material removal.
Innovation Solution
A work interface accessory that mounts on a friction stir welding head, enabling the rotation of a working tool to eliminate roughness and burrs, and perform other material removal operations by meshing with the head's rotating part, allowing for automated processing of the weld line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If friction stir welding is performed using a rotating pin and shoulder, then welding strength and joint quality are improved, but residual roughness and burrs are generated along the weld line
Solution Approach 1:
The patent combines the friction stir welding function and the surface finishing function into a single integrated tool. The tool includes a pin for welding, a shoulder for welding, and an integrated milling cutter or grinding element for surface finishing. This merging allows both welding and post-weld surface treatment to be performed in one operation, eliminating the need for separate operations and improving overall efficiency.
Solution Approach 2:
The integrated tool performs surface finishing actions immediately after welding while the material is still in its softened state from the friction heat. This preliminary action allows for easier material removal and surface smoothing before the material fully cools and hardens, improving the quality of surface treatment.
2Manufacturing precision
If additional work tools are needed for material removal operations, then welding quality can be improved, but device complexity and operational complexity increase
Solution Approach 1:
The patent integrates multiple functions (welding and surface finishing) into a single tool assembly that attaches to the friction stir welding head. This eliminates the need for separate work tools and reduces the complexity of tool changes and configurations. The integrated tool is driven by the same rotation mechanism as the welding pin, simplifying the drive system.
Solution Approach 2:
The integrated tool serves multiple functions: it performs friction stir welding with the pin and shoulder, and simultaneously or sequentially performs surface finishing operations with the integrated milling cutter or grinding element. This multi-functionality reduces the need for multiple specialized tools and simplifies the overall equipment configuration.
3Ease of operation
If separate operations are used for welding and surface finishing, then operational flexibility is maintained, but productivity and time efficiency decrease
Solution Approach 1:
The patent combines welding and surface finishing operations into a single integrated tool that can perform both functions in one pass. This merging significantly improves productivity by eliminating the need for separate operations, tool changes, and repositioning. The integrated tool maintains operational flexibility through programmable control of the different functions.
Solution Approach 2:
The integrated tool allows for continuous operation where welding and surface finishing are performed in sequence without interruption or tool changes. The rotation of the tool continues throughout both operations, maintaining continuous useful action and maximizing productivity.
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 quick and automated removal of roughness and burrs from the weld line, reducing post-processing time and improving the quality of welds by integrating the working tool directly with the welding head's operation.
Implementation Method 1
a projecting rotating pin bordered by a shoulder is rotated by the head and moved along the joint between the two edges of the parts, to create a weld line along this joint by friction stirring the material of the parts
Data Source
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AI summary
The invention relates to a working interface accessory (10), comprising an outer body (11) having a wall (12) delimiting a housing (120) for the introduction of a rotating part of a friction stir welding head, an upper plate (13) comprising parts (131) for fixing against the head, a central rotating shaft (14) protruding to carry a working tool, the shaft (14) comprising an internally toothed coupling sleeve (15) to allow the rotation of the shaft (14), when an externally toothed ring of the rotating part of the head rotates in the sleeve (15).