Elementary Panel End Machining for Accurate Friction Stir Welding

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Solution Overview

Problem

The existing methods for preparing elementary metal panels for friction stir welding are complex, time-consuming, and lack accuracy, requiring manual measurement and machining steps to remove cladding, which are costly and unreliable, especially for aeronautical structures where stringent quality standards are required.

Innovation Solution

A machining device with guiding and pressure members that constrains the metal panel in a predetermined plane, allowing for precise removal of cladding without prior measurement, ensuring accurate thickness reduction and improved reliability by maintaining the panel in a stable frame of reference during machining.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual measurement and machining steps are used to remove cladding, then the cladding can be removed, but the process becomes complex, time-consuming, and unreliable

Engineering Contradiction:

Improvereliability of cladding removalVSAvoidcomplexity of measurement and machining process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts the measurement step entirely from the process by using a machining device that directly references the theoretical trajectory without requiring prior measurement of the actual panel position. The machining device uses guiding members aligned with the theoretical trajectory to automatically compensate for vertical deviations, eliminating the need for separate measurement and correction calculations.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The machining device serves multiple functions: it guides the panel using guiding members aligned with the theoretical trajectory, positions the machining tool according to the same trajectory, and performs the cladding removal all in one integrated system. This multi-functionality eliminates the need for separate measurement and machining operations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Measurement precision

If contact measurement is performed to determine vertical deviation, then the position can be measured, but the process is long, costly, and does not meet reliability requirements

Engineering Contradiction:

Improveprecision of panel position measurementVSAvoidtime required for measurement step

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent uses preliminary action by aligning the guiding members and machining tool with the theoretical trajectory before machining begins. This pre-alignment allows the system to automatically compensate for vertical deviations during machining without requiring time-consuming measurement steps to determine the actual panel position.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The machining device creates a mechanical copy of the theoretical trajectory through its guiding members and tool positioning system. Instead of measuring the actual panel position and calculating corrections, the system uses guiding members that follow the theoretical trajectory to automatically guide both the panel and machining tool, effectively copying the ideal path without measurement.

Inventive Principle:

Principle #26Copying

3Productivity

If the cladding is not fully removed, then the machining time is reduced, but the cladding material mixes with the central metal body degrading weld quality

Engineering Contradiction:

Improvemachining speedVSAvoidprecision of cladding removal thickness

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system uses feedback by continuously referencing the theoretical trajectory during machining. The guiding members and machining tool are positioned based on the predetermined theoretical trajectory, which provides continuous positional feedback to ensure the machining depth is precisely controlled to match the actual cladding thickness at each location.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces the mechanical measurement system with a trajectory-based positioning system. Instead of using contact measurement tools to determine panel position and calculate machining depth, the system uses guiding members aligned with the theoretical trajectory to automatically position the machining tool at the correct depth based on the predetermined path.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Object-generated harmful factors

If the cladding is over-removed, then the cladding is fully eliminated, but the central metal body thickness becomes too small for optimal welding

Engineering Contradiction:

Improvecladding contamination in weldVSAvoidprecision of thickness control

Core Design Contradiction:

Object-generated harmful factorsVSManufacturing precision

Solution Approach 1:

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS11752570B2Device and method for the machining of an end of an elementary panel for its friction stir welding

Publication Date: 2023.09.12 AIRBUS ATLANTIC (SAS)

AI summary

Device for machining an end of an elementary panel for its subsequent friction stir welding, the elementary panel comprising a metal body defining two opposite faces, the machining device comprising a chassis, at least two guiding members configured to guide a first face of the elementary panel, at least one machining tool mounted on the chassis, the machining tool being positioned between the two guiding members and at least one pressure member mounted on the chassis and configured to exert a pressure on a second face of the elementary panel so as to press the elementary panel against the guiding members along the horizontal reference direction.