Friction Stir Welding Tool Support Medium for Force Control
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Solution Overview
Problem
Existing friction stir welding devices face challenges in accurately controlling the welding force due to minute errors in workpiece positioning, which can lead to welding errors, requiring complex hydraulic pressure control systems.
Innovation Solution
A friction stir welding device with a tool holding unit and support medium that allows for precise positioning and loading of the tool, enabling accurate pressing and maintaining a consistent welding force despite errors in workpiece surface positioning, using a load applying unit to ensure the tool is securely adhered to the workpiece surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If hydraulic pressure feedback control is used to maintain welding force, then welding force control is improved, but device complexity increases
Solution Approach 1:
A support medium (roller or support member) is introduced as an intermediary between the tool and the workpiece surface. This support medium mechanically maintains the positional relationship of the tool's first shoulder surface relative to the workpiece surface, eliminating the need for complex hydraulic pressure feedback control systems while ensuring consistent welding force application.
2Force
If hydraulic pressure sensing and feedback control is implemented, then welding force accuracy is improved, but ease of operation deteriorates
Solution Approach 1:
The support medium automatically maintains the tool's positional relationship with the workpiece surface through mechanical contact. The roller or support member self-adjusts to surface variations, providing welding force accuracy without requiring operator intervention or complex control operations.
3Manufacturing precision
If minute positioning errors are detected and corrected through feedback, then welding precision is improved, but loss of time increases
Solution Approach 1:
The support medium is positioned in advance to maintain the tool's first shoulder surface at the correct position relative to the workpiece surface. This preliminary mechanical arrangement prevents positioning errors before welding begins, eliminating the need for time-consuming error detection and correction during the welding process.
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
The device achieves accurate friction stir welding by maintaining a consistent welding force and minimizing the impact of surface errors, allowing for precise control and improved welding quality with a simpler configuration.
Implementation Method 1
a support medium formed to have a predetermined relative positional relationship in the direction facing the workpieces with respect to the first shoulder surface of the tool and configured to support the tool holding unit on the surface of the workpieces
Implementation Method 2
generating frictional heat at workpieces surface by rotating a tool at a welding place of the workpieces in a state in which a predetermined welding pressure is applied to a surface, which is referred to as a shoulder surface of the tool
Implementation Method 3
The load applying unit is configured to apply a preset load to the support medium toward the workpieces disposed at the workpiece disposition unit
Data Source
Figure 1
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Figure 4~5
AI summary
A friction stir welding device (1) includes a workpiece disposition unit (2) at which workpieces (W) is disposed, a main body section (3) disposed at a surface (W4) of the workpieces (W) disposed at the workpiece disposition unit (2), a tool holding unit (4) formed in the main body section (3) to enable advance and retreat in a direction facing the workpieces (Z), which is a direction approaching and separating from the workpieces (W) disposed at the workpiece disposition unit (2), and configured to hold a tool (100), and a support medium (5) formed to satisfy a predetermined relative positional relationship in the direction facing the workpieces (Z) with respect to a first shoulder surface of the tool (100) attached to the tool holding unit (4) and configured to support the tool holding unit (4) on the surface (W4) of the workpieces (W) disposed at the workpieces disposition unit (2).