Spring-Biased Friction Stir Tool for Stable Pin Insertion Control
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Solution Overview
Problem
Existing joining devices for friction stir welding, particularly those using load control, have a complex structure and are expensive, making them unsuitable for use with low-cost machining centers that can only perform position control.
Innovation Solution
A rotating tool and joining device configuration that includes a stir member biased by an elastic member and restricted by a restriction member, allowing for load control by controlling the insertion depth of the stir pin into the to-be-joined members, even when attached to a machining center.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If load control is implemented using a robot-based joining device, then joining quality and press-in depth control are improved, but device complexity and cost increase significantly
Solution Approach 1:
A force generator (elastic member) is introduced as an intermediary between the machining center and the rotating tool. This elastic member generates a predetermined force that pushes the rotating tool toward the workpiece, enabling load control without requiring complex robot-based systems. The force generator acts as a mediator that converts the simple position control capability of the machining center into effective load control.
Solution Approach 2:
The elastic member automatically generates the necessary plunging force through its elastic deformation. The system self-regulates the load by allowing the elastic member to compress and expand based on the resistance encountered during friction stir welding, eliminating the need for external load sensing and control systems.
2Device complexity
If position control is used with a machining center, then device complexity is reduced and cost decreases, but load control capability is lost
Solution Approach 1:
The force generator serves as a mechanical intermediary that provides continuous plunging force without requiring the machining center to perform complex force control operations. The elastic member translates the positional movement of the machining center into controlled loading on the workpiece.
Solution Approach 2:
The system changes the control parameter from direct force control (requiring robot) to position control with elastic force generation (using machining center). By selecting an elastic member with appropriate stiffness characteristics, the system achieves effective load control through simple positional movement.
3Adaptability or versatility
If the stir member is allowed to move freely in the axial direction, then load adaptation is improved, but excessive deformation and breakage occur
Solution Approach 1:
The elastic member provides beforehand cushioning by absorbing excess force through elastic deformation. When the rotating tool encounters high resistance or the stir member approaches its movement limit, the elastic member compresses to cushion the impact, preventing sudden shocks that could cause breakage.
Solution Approach 2:
The system transitions from a static connection to a dynamic one where the stir member can move axially within limits. The elastic member enables controlled dynamics, allowing the stir member to adapt to varying load conditions while the restriction member ensures the movement remains within safe boundaries to prevent failure.
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
Enables stable and accurate friction stir welding on both soft and hard materials by controlling the insertion depth of the stir pin using an elastic member, preventing excessive deformation and breakage, while maintaining a simple and cost-effective setup.
Implementation Method 1
an elastic member (70) that biases the stir member (50) toward a distal end side in the axial direction of the rotating shaft (12)
Implementation Method 2
a restriction member (100) that restricts movement of the stir member (50) toward a base end side in the axial direction of the rotating shaft (12)
Implementation Method 3
a stir member (50) including a stir pin (51) that performs friction stirring on to-be-joined members (2)
Data Source
AI summary
Provided is a rotating tool used in a joining device, the rotating tool including: a main body including a fixation portion and a rotating shaft; a stir member including a stir pin that performs friction stirring on the to-be-joined members, the stir member provided to be rotatable by receiving the rotating force from the rotating shaft and provided in the main body to be movable in an axial direction of the rotating shaft; an elastic member configured to bias the stir member toward a distal end side in the axial direction of the rotating shaft; and a restriction member configured to restrict movement of the stir member toward a based end side in the axial direction of the rotating shaft.