Friction Stir Welding Tool Holder With Integrated Thermal Sensing
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Solution Overview
Problem
In friction stir welding, monitoring the stir temperature is crucial but existing methods often compromise the strength of the tool head, leading to reduced performance.
Innovation Solution
A friction stir welding tool holder equipped with a thermal sensor integrated into the static shaft shoulder assembly or tool locking ring, allowing real-time temperature monitoring without compromising the structural strength of the tool head.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a thermal sensor is integrated into the tool head structure, then temperature monitoring capability is improved, but structural strength deteriorates
Solution Approach 1:
The tool holder is divided into functionally independent components: the tool holder cone body, the tool locking ring, and the thermal sensor assembly. The thermal sensor is integrated into the tool locking ring rather than the main cone body, segmenting the monitoring function from the primary load-bearing structure. This allows temperature sensing without compromising the overall structural integrity of the tool holder.
Solution Approach 2:
The tool locking ring serves as an intermediary component that bridges the thermal sensor and the tool holder structure. The sensor is mounted on the tool locking ring, which itself is a load-bearing component that transmits forces between the tool and the holder. This intermediary arrangement allows the sensor to access temperature data while the tool locking ring maintains its structural function, effectively decoupling the sensing function from the primary load path.
2Measurement precision
If the tool head structure is modified to accommodate temperature sensing, then temperature detection capability is improved, but device complexity increases
Solution Approach 1:
The thermal sensor assembly is merged with the existing tool locking ring component. Rather than adding a separate sensor housing or modifying the main cone body, the sensor is integrated directly into the tool locking ring's existing structure. The tool locking ring's cavity and threaded hole are utilized to mount the sensor, combining the locking function and sensing function into a single integrated component, thereby minimizing additional complexity.
Solution Approach 2:
The tool locking ring is designed to serve multiple functions: it provides the mechanical locking interface for the tool, transmits axial and radial forces, and now also serves as the mounting platform for the thermal sensor. This multi-functionality approach allows the same component to handle both structural and sensing tasks, reducing the need for additional dedicated sensor housing or mounting structures.
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 precise temperature monitoring of the cutting tool during the welding process, maintaining structural integrity and ensuring consistent welding quality.
Implementation Method 1
a thermal sensor, inserted in the thermal sensing slot to sense a temperature of the cutting tool at any time
Implementation Method 2
a tool head of a cutting tool rotating at a high speed is inserted into two pieces of fitted metal, heat generated by friction of the tool head rotating at a high speed and the two pieces of metal
Data Source
AI summary
A friction stir welding tool holder is provided and includes: a tool holder cone, an end thereof is connected to the rotating spindle, a cone flow channel is formed therein, the cone flow channel has a valve, and the tool holder cone further has a tool locking ring, and the tool locking further has a tool accommodation groove axially arranged and a thermal sensing slot laterally arranged; a cutting tool, axially movable relative to the tool holder cone, where the cutting tool is arranged in the tool accommodation groove and has a machining end protruding from the tool accommodation groove; a torque transmission system, arranged between the tool holder cone and the cutting tool to transmit torque from the tool holder cone to the cutting tool; and a thermal sensor, inserted in the thermal sensing slot to sense a temperature of the cutting tool at any time.