FSW Joint Deburring with Coaxial Guide Roller Depth Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional deburring tools face challenges in achieving high-precision burr removal on metal joints welded by friction stir welding due to interference from stoppers, making it difficult to remove burrs accurately without scratching the metal surfaces.
Innovation Solution
A deburring device equipped with a cutting blade, a guide roller that rotates coaxially with the cutting blade, a mover to move the deburrer along the joint, and an orientation controller using a force sensor to control the deburrer's position based on the surface shape, ensuring precise burr removal without excessive cutting or scratching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a stopper is used to control cutting depth, then the cutting depth can be adjusted, but the stopper interferes with the burrs and makes high-precision deburring difficult
Solution Approach 1:
The patent removes the stopper component from the deburring tool and replaces it with a guide roller that contacts the base metal surface. This extraction eliminates the interference problem where the stopper would contact and interfere with the burrs, while still maintaining cutting depth control through the guide roller's contact with the workpiece surface.
Solution Approach 2:
The guide roller serves as an intermediary component between the cutting blade and the workpiece surface. Instead of using a stopper that directly limits blade descent, the guide roller mediates the depth control by contacting the base metal surface and preventing the cutting blade from exceeding the appropriate depth, thereby avoiding burr interference.
2Manufacturing precision
If the cutting blade is positioned close to the metal surface for precise deburring, then burr removal precision improves, but the risk of scratching the metal surface increases
Solution Approach 1:
The guide roller acts as a protective intermediary that contacts the base metal surface before the cutting blade does. This ensures the cutting blade maintains the correct distance from the surface, enabling precise burr removal while preventing the blade from contacting and scratching the metal surface.
Solution Approach 2:
The guide roller performs a preliminary action by contacting and following the contours of the base metal surface ahead of the cutting blade. This preliminary contact establishes the correct cutting depth and orientation, ensuring the blade operates at the optimal distance for precise deburring without surface damage.
3Adaptability or versatility
If the deburring tool follows curved or uneven joint surfaces, then adaptability to different joint shapes improves, but controlling the cutting depth consistently becomes difficult
Solution Approach 1:
The guide roller is designed to dynamically adapt to curved and uneven joint surfaces by following their contours. As the roller contacts and follows the varying surface geometry, it automatically adjusts the cutting blade's position and orientation, maintaining consistent cutting depth across different surface shapes without requiring manual intervention.
Solution Approach 2:
The guide roller provides continuous feedback about the joint surface geometry through its contact points. This feedback mechanism allows the cutting blade to automatically adjust its position and orientation in real-time, maintaining consistent cutting depth even when following curved or uneven surfaces, thereby resolving the contradiction between adaptability and precision.
Data Source
AI summary
The present invention provides a deburring device capable of removing a burr with high precision. A deburring device 1 for removing a burr formed on a joint of metal members joined together by friction stir welding (FSW) includes: a deburrer including a cutting blade that cuts the burr formed on the joint, a drive mechanism that drives the cutting blade to rotate, and a guide roller that has a diameter equal to or smaller than the cutting blade, is able to rotate coaxially with the cutting blade, and makes contact with a surface of the joined metal members at the joint to control the amount of cutting by the cutting blade; a mover that moves the deburrer along the joint; and an orientation controller that controls an orientation of the deburrer according to the shape of the surface of the joined metal members.