Spring-Biased FSP Spindle for Consistent Penetration on Uneven Surfaces
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Solution Overview
Problem
Conventional friction stir processing (FSP) tools require precise load measurement and adjustment to avoid defects, especially when working with uneven or non-planar workpieces, as they struggle to maintain consistent axial force and penetration depth due to variations in the workpiece surface.
Innovation Solution
The implementation of a dynamic load system using a biasing element that axially overlaps the spindle, allowing for adaptive axial force adjustment and bit movement in response to workpiece surface changes, enabling consistent penetration and reduced defects in FSP without user intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional FSP tools are used on non-planar workpieces, then the process can be performed, but consistent axial force and penetration depth cannot be maintained due to surface variations
Solution Approach 1:
The patent applies the dynamics principle by implementing a biasing element (spring) that allows the FSP tool to dynamically adjust its axial position in response to workpiece surface variations. The spring-loaded mechanism enables the tool to maintain consistent axial force and penetration depth on non-planar surfaces by automatically compensating for height changes, transforming a static tool into a dynamic adaptive system.
Solution Approach 2:
The biasing element provides self-service functionality by automatically adjusting the tool's axial position without external intervention. The spring mechanism self-regulates the axial force applied to the workpiece, eliminating the need for precise load measurement and manual adjustment during the FSP process, thereby maintaining consistent penetration depth on varying surfaces.
2Manufacturing precision
If precise load measurement and adjustment systems are implemented, then FSP quality can be maintained, but device complexity increases
Solution Approach 1:
The biasing element serves as a self-regulating mechanism that automatically maintains appropriate axial force without requiring external load measurement or control systems. The spring mechanism inherently provides the necessary force adjustment, eliminating complex instrumentation and control hardware while maintaining FSP quality consistency.
Solution Approach 2:
The biasing element acts as an intermediary between the FSP tool and the workpiece, mediating the axial force application. This mechanical intermediary simplifies the overall system by replacing complex electronic load measurement and control systems with a passive mechanical element that naturally regulates the interaction between tool and workpiece.
3Manufacturing precision
If axial force is increased to maintain penetration on uneven surfaces, then penetration depth is maintained, but risk of phase change and material defects increases
Solution Approach 1:
The dynamic biasing element allows the axial force to be applied gradually and adaptively rather than as a fixed high load. The spring mechanism enables the tool to follow the workpiece surface contour, maintaining consistent penetration depth without applying excessive force that could cause phase change or material defects.
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 solution enhances the precision and efficiency of FSP by maintaining consistent axial force and penetration depth, even on non-planar surfaces, reducing defects and allowing for faster welding with increased translational speeds and stronger welds.
Implementation Method 1
The biasing element supports the driver and is configured to apply a biasing force in an axial direction
Implementation Method 2
FSP uses the motion of a pin pressed against the surface of a weldable material to generate heat and friction to move the weldable material
Implementation Method 3
The material can plasticize and physically stir together with a second material to which the first material is joined
Data Source
AI summary
A device for friction stirring a workpiece material includes a body, a spindle, a driver, and a biasing element. The spindle is configured to rotate around a rotational axis. The driver is rotationally coupled to the spindle. The biasing element supports the driver and is configured to apply a biasing force in an axial direction, wherein the biasing element axially overlaps the spindle.