Link Rod Friction Stir Welding via Notch Segmentation
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Solution Overview
Problem
Existing link rod manufacturing methods face challenges in achieving high reliability and efficiency due to the need for flush tool traveling surfaces during friction stir welding, which requires multiple small diameter portions and reduces production efficiency.
Innovation Solution
The method involves forming a link rod with parallel first and second walls and a third wall, where a notch is created on the third wall, allowing an engaging projection on the bush mounting bracket to support the walls and form a plane tool traveling surface, enabling continuous friction stir welding along the butt portions and efficient cutting to produce multiple link rods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If friction stir welding is performed from outside of a pipe member with pressing, then welding reliability is improved, but the pipe member may be dented and production efficiency decreases
Solution Approach 1:
The invention inverts the conventional welding approach by performing friction stir welding from the inside of the pipe member rather than from the outside. The tool is inserted through the notch in the third wall and welds the first and second walls from the interior, eliminating denting issues while maintaining welding reliability and enabling continuous processing for improved production efficiency
2Reliability
If multiple small diameter portions are created for engagement, then flush butt portions are achieved for reliable welding, but device complexity increases and production efficiency deteriorates
Solution Approach 1:
The invention segments the third wall by creating a notch that divides it into first and second walls, which are then engaged with the bracket by the engaging projection. This segmentation achieves the flush butt portion requirement for reliable welding while using a single continuous bracket structure rather than multiple separate components, thereby reducing overall device complexity
Solution Approach 2:
The notch in the third wall acts as an intermediary structure that enables the engaging projection to support the first and second walls. This intermediary feature facilitates the formation of flush butt portions without requiring multiple separate engagement components, simplifying the overall structure while ensuring welding reliability
3Reliability
If tool traveling surfaces are formed without height difference, then welding reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The invention performs preliminary action by forming the notch in the third wall before the friction stir welding process. This pre-formed notch allows the engaging projection to automatically position and support the first and second walls at the correct height, ensuring flush butt portions and tool traveling surfaces without height differences are achieved during assembly, thereby maintaining welding reliability while simplifying the manufacturing 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
This approach ensures high-reliability friction stir welding by preventing tool deformation and allows for simultaneous joining and easy separation of link rods, thereby improving production efficiency and precision.
Implementation Method 1
the arm portion is joined to the bush mounting bracket by friction stir welding along the butt portion between each of the ends of the first and second walls and the bush mounting bracket
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3C
AI summary
In a link rod manufacturing method, a bracket material (14) having a ring portion and a mounting projection (15) is made by extrusion molding a material at the length corresponding to a plurality of brackets. On a forward end of the mounting projection (15), an engaging projection (17) with upper and lower steps (7a, 7a) is formed. An arm (2) is made by extrusion molding and regular-size cutting a material in a substantially I-shaped configuration which has a pair of first and second walls (20, 21) parallel extending on upper and lower sides and a third wall (22) crossing at a right angle and connecting these walls. A notch (23) is formed on an end of the third wall (22). When the engaging projection (17) is engaged with the notch (23), each of ends of the first and second walls (20, 21) on the side of ends 2a of the arm 2 is fitted onto the step (7a, 7a) and butted against a vertical wall (17b). Surfaces in the vicinity of butted portions (6) formed in this way forms a plane tool traveling surface and are supported on the insides thereof by the engaging projection (17) to prevent deformation. Therefore, the friction stir welding is carried out along the butt portion (6).