Friction Stir Welding Head Accessory for In-Line Burr Removal
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Solution Overview
Problem
Friction stir welding heads generate residual protruding burrs and asperities along the welding line, and lack the ability to automate the addition of work tools, necessitating additional operations for removal or material processing.
Innovation Solution
A work interface accessory that can be assembled and disassembled from a friction stir welding head, featuring a central shaft for rotating a work tool to eliminate burrs and asperities, driven by the head's rotation, with a system of clamps for secure fastening and a cradle for storage and positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If friction stir welding is performed using a rotating pin and shoulder, then welding of two parts is achieved, but residual protruding burrs and asperities are generated along the welding line
Solution Approach 1:
The invention combines the friction stir welding operation with a trimming operation by integrating a work tool (milling tool or file) into the welding head assembly. The work tool is driven in rotation by the same motor that drives the friction stir pin, allowing both welding and burr removal to be performed simultaneously in one pass, thereby eliminating the harmful burrs and asperities generated during welding.
2Extent of automation
If a friction stir welding head is used alone, then welding operation is performed, but additional work tools cannot be added in an automated manner
Solution Approach 1:
The invention creates a multi-functional welding head assembly where a single device performs multiple operations. The work interface accessory includes a work tool holder that can accommodate different types of work tools (milling tools, files, etc.), allowing the same friction stir welding head to perform welding, trimming, and other material removal operations automatically without requiring tool changes or additional equipment.
3Manufacturing precision
If additional operations are performed to eliminate burrs and asperities, then welding line quality is improved, but processing time and complexity increase
Solution Approach 1:
The invention performs the trimming operation simultaneously with the welding operation rather than as a separate subsequent step. The work tool is positioned to trim the welding line as the friction stir pin creates the weld, so the burr removal action is performed preliminarily during the welding process itself, eliminating the need for separate post-welding processing steps and reducing total processing time.
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 quick and efficient removal of burrs and asperities from the welding line by utilizing the work tool integrated with the friction stir welding head, reducing the need for additional processing steps and improving the automation of material removal operations.
Implementation Method 1
an externally toothed ring gear of the rotating portion of the friction stir welding head is introduced into the internally toothed coupling sleeve and rotates in the internally toothed coupling sleeve around the axis of rotation
Implementation Method 2
a protruding rotating pin bordered by a shoulder is rotated by the head and is moved along the joint between the two edges of the parts, to make a welding line along this joint by friction stir of the material of the parts
Implementation Method 3
the work interface accessory allows driving in rotation a work tool making it possible to eliminate the residual protruding burrs and asperities appearing along the welding line
Data Source
AI summary
The invention relates to a work interface accessory, comprising an external body having a wall delimiting a recess for the introduction of a rotating portion of the friction stir welding head, an upper plate comprising fastening portions against the head, a central rotating shaft projecting to carry a work tool, the shaft comprising an internally toothed coupling sleeve to allow the shaft to be driven in rotation, when an externally toothed ring gear of the rotating portion of the head rotates in the sleeve.