AU2005200372A1 - Compound machining device and friction stir welding method - Google Patents

Description

AUSTRALIA

PATENTS ACT 1990 DIVISIONAL APPLICATION NAME OF APPLICANT(S): HITACHI, LTD.

ADDRESS FOR SERVICE: DAVIES COLLISON CAVE Patent Attorneys 1 Nicholson Street Melbourne, Victoria 3000 INVENTION TITLE: "COMPOUND MACHINING DEVICE AND FRICTION STIR WELDING

METHOD"

The following statement is a full description of this invention, including the best method of performing it known to us: FIELD OF THE INVENTION The present invention relates to a method and device for cutting and friction-stir-welding metal material. For example, the present invention is preferably applied to machining and assembling of mechanical parts or structural parts.

DESCRIPTION OF THE RELATED ART When machining and assembling mechanical parts or structural parts and the like, separate machining devices are used; a cutting machine tool is used for the cutting process, and various welding/welding devices are used for the welding and assembling process.

Compound machining carried out by a single cutting machine tool usually relates to combination of cutting processes, such as turning and rotary tool machining using a compound engine lathe, or a rotary tool machining and bite machining using a machining center. One example of a combination of a cutting process with another process is the combination of a rotary tool machining and a laser hardening.

One example of a method for welding members is a friction stir welding method (refer to Japanese Patent Laid-Open Publication No. 11-90655, USP No. 6050474). The method includes inserting a round shaft (called a rotary tool) to a joint portion, rotating and moving the rotary tool along the 1 joint portion, thereby heating, mobilizing, plasticizing and solid-phase welding the joint portion. The rotary tool comprises a small-diameter portion (called a pin) to be inserted to the joint portion, and a large-diameter portion (called a shoulder) positioned to the exterior. The small-diameter portion and the large-diameter portion are coaxial. The large-diameter-portion side is rotated. The joint portion is provided with a convex.

Further, as disclosed in Japanese Patent Laid-Open Publication No. 9-508073 (EP0752926B1), the rotary tool is tilted when being inserted to the member. It is tilted so that the small-diameter portion of the rotary tool is positioned frontward than the large-diameter portion thereof in the direction of movement of the tool. In other words, the rotary tool is tilted rearwards.

SUMMARY OF THE INVENTION P:\opa\scI2S55570 Div I of 23101-0.doc.3I/O1/O -3- According to one aspect of the present invention, there is provided a friction stir welding device comprising: a detector for detecting the torque current value of a rotation axis of a friction stir welding tool during a friction stir welding process; and a control unit for controlling the depth of insertion of said friction stir welding tool to a work object based on the detected value from said detector.

According to a second aspect of the present invention, there is provided a friction stir welding device comprising: a main shaft for rotating a friction stir welding tool; a first moving device for relatively moving said main shaft against a work object; a second moving device for relatively moving said main shaft along the joint line of said work object; a detector for detecting the torque current value of said main shaft when inserting said friction stir welding tool to said work object; and a control unit for correcting the coordinate value of said work object based on the detected value of said detector, and for driving said first moving device based on the corrected value.

According to a third aspect of the present invention, there is provided a friction stir welding method comprising the steps of: r7f P:€opa1\mAI2555570 Div I of 23101.OI. do-24/OI/05 -4detecting the torque current value of a rotation axis of a friction stir welding tool during a friction stir welding process; and controlling the depth of insertion of said friction stir welding tool to a work object based on the detected value.

According to a fourth aspect of the present invention, there provided A friction stir welding method comprising the steps of: detecting the toque current value of a rotation axis when inserting a friction stir welding tool to a work object; correcting the coordinate value of said work object based on said detected value; and controlling the relative amount of movement of said friction stir welding tool against said work object based on the corrected value.

According to a fifth aspect of the present invention, there is provided a friction stir welding method comprising the steps of: when inserting a friction stir welding tool to a work object, detecting the current flowing in said tool being transmitted when said tool contacts said work object; correcting the coordinate value of said work object based on said detected value; and controlling the relative amount of movement of said friction stir welding tool against said work object based on the corrected value.

I

I P:op\sew\l 2555570 Div I of2310101 .doc-24//005 BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view showing the machining device according to one embodiment of the present invention; FIG. 2 is a perspective view showing the cutting process performed by the compound machining device; FIG. 3 is a perspective view showing the friction stir welding process performed by the compound machining device; I r FIG. 4 is a vertical cross-sectional view showing the friction stir welding process; FIG. 5 is a diagram showing the relationship between the insertion depth of the friction stir welding tool and the torque current; FIG. 6 is a flowchart showing the machining steps according to one embodiment of the present invention; FIG. 7 is a schematic view showing the machining device of another embodiment of the present invention; FIG. 8 is a schematic view showing the machining device of another embodiment of the present invention; and FIG. 9 is a schematic view showing the machining device of yet another embodiment of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS One preferred embodiment of the present invention related to a machining-center-type compound machining device is explained with reference to FIGS. 1 through 6. The device comprises a table (moving base) 11 capable of moving in the direction of axis X, a moving base 31 mounted on a beam 21 positioned above the table 11 and capable of moving in the direction of axis Y, a moving base 32 mounted on the moving base 31 and capable of moving in the direction of axis Z, a rotary base 33 mounted on the moving base 32 and capable of rotating in the direction of axis C, a rotary base 34 mounted on the rotating base 33 and capable of rotating in the direction of r'I i I axis B, and a main shaft 35 mounted on the rotary base 34 for rotating the tool fixed thereto. The rotary base 34 comprises a motor for rotating the main shaft A cutting tool 51 or a friction stir welding tool 52 can be selectively fixed to the main shaft 35. The main shaft can be rotated in speeds appropriate for tool 51 or tool 52.

A tool storage device 40 is not shown in the drawing, but can store a plural number of cutting tools 51 and friction stir welding tools 52. Through the use of a tool exchange device (not shown), the tools can be exchanged between the main shaft and the tool storage device 40, thereby mounting a desired tool 51 or 52 to the main shaft 35. Further, not only the tools but also a so-called machining head including the tool, the bearing of the tool and the like can be exchanged. A known technology is utilized in the driving means driving each moving base 11, 31, 32 enabling movement in directions X, Y and Z, the driving means of rotary bases 33 and 34, and the tool exchange device.

A compound machining device preferably applied to the cutting and the friction stir welding of a tridimensional structure is obtained by simultaneously controlling five axes, which are the three linear movement axes and the two axial rotation axes.

A work object 101 is mounted on the table 11. The work object 101 is a panel member in the shape of a curved plate.

FIG. 2 is referred to in explaining the cutting process.

r i In a five-axis cutting process, the main shaft 35 (the rotation axis of tool 51 or 52) can be moved to take a right angle to the curved surface of the work object 101. Therefore, in comparison to the conventional processes utilizing two or three axes not capable of being tilted against the position of the tool, the present embodiment realizes a shorter tool protrusion length, enabling the tool to maintain great rigidity.

Therefore, the present device enables to provide a highly efficient cutting process with increased cutting speed without causing much chatter or vibration.

Moreover, in the five-axis cutting process, the position of the main shaft 35 can be set with freedom, so the axis A of the cutting tool 51 can be tilted rearward from the normal R at the joint of the work object, in other words, the tool can be tilted rearwards against the curved surface during the process. In a flat tool, the cutting edge can be partially used for cutting. Therefore, compared to the cutting process where the whole surface is used, the cutting resist is reduced, thereby enabling a highly efficient cutting process with increased cutting speed without causing much chatter or vibration.

FIG. 3 and FIG. 4 will now be referred to in explaining the friction stir welding. The abutted area of work objects 101 and 102 are welded. The abutted portions on the ends of objects 101 and 102 are each provided with convex portions 101b and 102b protruding in the upper direction. The work objects I i i 101 and 102 are manufactured by the above-explained cutting process. FIG. 3 does not show convex portions 101b and 102b.

FIG. 4 shows the convex portions 101b and 102b. The work objects 101 and 102 are panels having curved surfaces. The friction stir welding tool 52 comprises a large-diameter portion 52b and a small-diameter portion 52c mounted on the tip of the portion 52b. The small-diameter portion 52c is inserted to the area to be welded together. The lowermost end of the large-diameter portion 52b is positioned between the peak of the convex portions 101b, 102b and the line extended from the upper surface of the work object excluding the convex portions 101b, 102b.

The width of the two convex portions 10b and 102b is greater than the diameter of the large-diameter portion 52b. The axis A of the tool 52 is tilted so that the axial center of the large-diameter portion 52b is positioned behind the axial center of the small-diameter portion 52c in the direction of movement of the tool 52. The friction stir welding is carried out by moving the tool 52 along the abutted portion (welding line) while rotating the tool 52.

The work objects 101 and 102 are mounted on the table 11 via a supporting base (not shown). The objects 101 and 102 are fixed strongly onto the table 11 via the supporting base.

Especially, the supporting base should exist below the abutted portion to be welded together. This is for supporting the large load generated when performing the friction stir welding.

Even when a gap exists between the abutted portions of the two work objects 101 and 102, the metal material of the convex portion 101b, 102b pressed by the large-diameter portion 52b will act as the source material for filling the gap formed thereto, so a good weld is obtained.

When the convex portions 101b and 102b do not exist, the welded area will become retreated since the large-diameter portion 52b is somewhat inserted to the surface of the objects 101 and 102 when the friction stir welding is performed.

It is effective to simultaneously control the five axes of the kinetic coordinate systems in order to move the tool along a curved surface while tilting the tool against the direction of movement, or to move the tool at a desired position.

Since there may be fabrication errors in the work objects 101 or 102, it is very difficult to maintain the insertion position of the tool accurately by moving the tool only based on an NC (numerical control) program.

FIG. 5 is a simplified diagram showing the relationship between the torque current of a motor rotating the tool 52 and the insertion depth of the tool 52 when the friction stir welding tool 52 is inserted to the work object. The insertion depth refers to the distance between the surface of the work objects 101 and 102 to the tip of the small-diameter portion 52c. Along with the increase in insertion depth of the tool 52, the torque current gradually increases, and reaches point Is. When the end of the large-diameter portion 52b of the tool 52 is started to be inserted to the work object, the torque current I leaps up to point Ia. The increase thereafter is gentle since the diameter of the large-diameter portion 52b is fixed. When tool 52 is inserted diagonally as aforementioned, the torque current increases gradually as insertion depth increases, while tool 52 is at a point of distance S between the point where the tip of small-diameter 52c begins to contact work object and the point where the edge of large-diameter 52b begins to contact work object, and reaches Is. When the edge of large-diameter 52b begins to be inserted into work object, the torque current I leaps while said large-diameter 52b is at a point of distance a between the edge of large-diameter 52b that is still away from said work object and the point where all of the edge of large-diameter 52b contacts work object, and reaches Ia.

Therefore, the insertion depth of the tool 52 is controlled so that the torque current value maintains a determined current value above Ia. Thus, a predetermined insertion depth can be maintained at all times even when the work object has a curved surface or has a fabrication error, which leads to achieving a good friction stir welding.

The torque current I of the tool 52 is obtained by detecting the current value of the motor of the main shaft 35. The main shaft 35 is rotated using an AC servomotor or a DC servomotor, so the torque current can be detected accurately. The torque current is used as a determination value in moving the base 32 up and down, so the best insertion depth can be maintained at all times. Moreover, by observing the torque current, the damage to the tool can be detected as well.

Moreover, the lowered position of the moving base 32 is detected based on the detection of the torque current value I, especially the specific value exceeding I a. Thereby, the position of the work objects 101 and 102 are detected. The difference between the detected value and the preset coordinate value of the objects 101, 102 or the NC (numerical control) data for moving the tool 52 is corrected. Thereby, the accurate insertion depth of the tool 52 to the work objects 101 and 102 can be obtained.

The position of the work objects 101 and 102 can also be detected by the method below. A power circuit via 11, 21, 31, 32, 33, 34, 35, tool 52 and work objects 101 and 102 is prepared.

A high-frequency power source and a detector is positioned midway of the circuit. At the beginning of the friction stir welding, the moving base 32 is lowered, and the tip of the small-diameter portion 52c of the tool 52 is positioned to contact the work objects 101 and 102. At this time, a high-frequency current circuit is composed, and the detector detects the current. The position of the tool 52 at the time of detection is computed. Thereafter, the difference between the detected value and the preset coordinate value of the objects 101 and 102 or the NC (numerical control) data formoving the tool 52 is corrected. According thereto, an accurate insertion depth is obtained. Thereafter, the insertion depth of the tool 52 can be controlled to a predetermined value based on the detection of the torque current I.

Next, the steps for manufacturing the work objects are explained with reference to FIG. 6. The work object 101 is mounted on the table 11, and mainly the upper surface thereof is cut using tool 51. At this time, the upper surface is cut leaving the convex portion 101b. Next, the work object 101 is removed, and the work object 102 is mounted on the table. The work object 102 goes through a similar cutting process. The work objects 101 and 102 are plates formed of aluminum alloy.

The plates have curved surfaces. The cutting process involves dry-cutting and dry-cleaning. When fixing the work object 102 onto the table 11, the object 102 is fixed via a support base, preparing for the next friction stir welding step (step Next, the work object 101 is mounted on the table 11 via the support base (not shown), abutted against the work object 102, and fixed to the table 11. Further, tools are exchanged between the main shaft 35 and the tool storage device 40 using the tool exchange device, and the friction stir welding tool 52 is mounted to the main shaft 35 (step Next, the main shaft 35 is rotated, and friction stir welding is performed to the abutted portions (step The tool 52 is rotated and lowered, and inserted to a predetermined position, thereby starting the friction stir welding. The vertical position of the objects 101 and 102 can either be detected using a high-frequency current, or by a torque current value I, as explained above. Based on the detected vertical position, the coordinates of the objects 101 and 102 are corrected.

Next, based on the NC data set in advance, the tool 52 is moved along the abutted portion (joint line). While the tool 52 is being moved along the joint line, the insertion depth of the tool 52 is controlled using the torque current value I.

The movement of the tool 52 along the joint line can be controlled using the coordinates set in advance (NC data), but can also be controlled using the data from the detector detecting the position of the joint line. The detector is an optical sensor, which is mounted on the rotary base 34. The detector detects the gap between the abutted portions or the edge of the convex portions 101b and 102b, thereby detecting the position of the abutted portions. The tool 52 is guided to the detected position. Moreover, the coordinates can be corrected by the detected data for guiding the tool 52. Further, an optical sensor can be used to detect the height of the convex portions 101b and 102b, and to control the insertion depth.

Next, after terminating the friction stir welding, the tool on the main shaft 35 is switched to the cutting tool 51 (step Next, the cutting process is performed (step S50). The cutting involves cutting the convex portions 101b and 102b of the abutted portions. Thereby, the abutted portions will substantially constitute the same surface as the curved surface of the other areas. This is effective when using the upper surface of the objects 101 and 102 as the outer surface of a product. Further, other curved surfaces can also be cut together with the convex portions.

Moreover, the outer peripheral portion of the integrated objects 101, 102 can be cut to a predetermined shape. Further, a hole, a screw or a recess can be formed on the curved surface using the cutting tool 51. Since a gap is formed when the object 101 is abutted against the object 102, holes and the like will be formed with higher accuracy after the friction stir welding is performed.

When the tool 52 is pulled out of the objects 101, 102 after the termination of the friction stir welding process, a hole is formed to that area. The hole can be cut to form a larger diameter hole, or can be processed as a screw. If a machine screw is to be provided, the position for pulling out the tool 52 should not be at the joint of the friction stir welding.

If the cutting is performed before the friction stir welding process, the oil used for the cutting process or the oil used for cleaning the object after the cutting process may provide a bad influence to the friction stir welding. Moreover, the facet may deteriorate the assemble accuracy of the two members.

However, such problems can be solved if the cutting process is performed after the friction stir welding process. The cutting of the two object members must be performed before the friction stir welding, but the cutting oil used in the process can be removed sufficiently using other devices.

In step S10, if the objects 101 and 102 can be abutted against each other to suit the conditions for the friction stir welding process, the objects 101 and 102 can be mounted on the table 11 at the abutted position for the cutting process. At this time, a support base should be positioned under the abutted portions.

Moreover, after performing a friction stir welding to one pair of objets using a first rotary tool, the rotary tool can be exchanged between the main shaft and the tool storage device, and the second joint area of the pair of objects can be friction-stir-welded using a second rotary tool.

The embodiment of FIG. 7 will now be explained. According to this embodiment, two machining devices 30 and 30B are provided to one table 11. The two machining devices 30 and are mounted on one beam 21. The compositions and functions of the two machining devices are the same as the first embodiment, and they are substantially identical. A cutting tool 51 is mounted on the main shaft of one machining device30. A friction stir welding tool 52 is mounted on the main shaft of another machining device 30B. Both ends of the beam 21 is protruded from the end of the table 11, and when one machining device is working, the other machining device can be sheltered to the protruded beam.

According to the present embodiment, there is no need for exchange of tools. Moreover, since great insertion force is needed for the friction stir welding process, the bearing and the like of the main shaft must have high strength. Further, the number of rotation of the main shaft is generally smaller in the friction stir welding process compared to the cutting process. Therefore, if the machining device 30 is specifically formed for cutting and the machining device 30B is specifically formed for friction stir welding, the friction stir welding device can be manufactured at a relatively low cost.

The embodiment of FIG. 8 will now be explained. It comprises a column 61 moving in the horizontal (X axis) direction, a moving base 63 mounted to the column 61 and moving in the vertical (Y axis) direction, a main shaft 65 mounted to the moving base 63 for rotating the mounted tool, a moving base 71 moving in the horizontal (Z axis) direction along the rotation axis of the main shaft 65, a rotary base 73 mounted to the moving base 71 and rotating in the direction of axis B, and a table 74 mounted to the rotary base 73 and rotating in the direction of axis A. A cutting tool 51 and a friction stir welding tool 52 can be exchanged between the main shaft 65 and the tool storage device 68 using a tool exchange device (not shown). The three linear moving axes and the two rotary axes, a total of five axes, can be controlled simultaneously.

The main shaft 65 is parallel, and the angle thereof cannot be changed. The table 74 is tilted against the main shaft to set the position of delayed inclination 8.

The embodiment of FIG. 9 will now be explained. A work object 111 is chucked onto a rotary base 81. The end portion I I of a work object 112 is inserted to the tip of the work object 111. The two objects are fit to one another. The end of the object 112 is supported by a tail stock 83. The abutted portion between theworkobject 111 andworkobject 112 is welded through friction stir welding. The end region of both objects are provided with convex portions 111b and 112b. A moving base 91 moves along the axial center of the rotary base 81 and further moves in the vertical direction. On the moving base 91 is provided a rotary base 92 that rotates at an angle of 45 degrees.

The rotary base 92 is provided with a main shaft 95 for rotating a tool 52. The rotary base 92 is also provided with a holder 96 for mounting a cutting tool 53. It is not necessary to rotate the holder 96. The cutting tool 53 is a bite-type tool.

The end of the work object 112 is inserted to the end of the cylindrical work object 111, abutting the ends together.

The abutted portion can be temporarily welded together by arc welding. The objects are then mounted on the rotary base 81, and the object 112 is supported by the tail stock 83. The rotary base 81 and the main shaft 95 are rotated to perform friction stir welding to the abutted portion. Next, the rotary base 92 is rotated to oppose the cutting tool 53 to the friction stir welded portion. Then, by rotating the rotary base 81, the convex portion of the welded portion is cut off. The friction stir welding process can be performed in the circumferential direction of the cylinder, or can be performed in any other direction. The cutting using the tool on holder 96 is performed

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P: p \s\I25557 Div I of23101-1O.do~-24/01/05 -19in the circumferential direction.

The object to be welded to the object mounted on a table or a rotary base can be positioned using a robot.

The technical scope of the present invention is not limited to the terms used in the claims or in the summary of the present invention, but is extended to the range in which a person skilled in the art could easily substitute based on the present disclosure. For example, the difference in the appearance or size of the compound machining device, or the difference in the size of the tools are included in the scope of the present invention.

According to embodiments of the present invention, the cutting process and the welding process can be performed by a single device, which enables to cut down the equipment cost, the installation space, the plant area, the lead time and the machining cost.

Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

The reference to any prior art in this specification is not, and should not be taken as, an acknowledgment or any form of suggestion that that prior art forms part of the common general knowledge in Australia.

Claims (7)

1. A friction stir welding device comprising: a detector for detecting the torque current value of a rotation axis of a friction stir welding tool during a friction stir welding process; and a control unit for controlling the depth of insertion of said friction stir welding tool to a work object based on the detected value from said detector.

2. A friction stir welding device comprising: a main shaft for rotating a friction stir welding tool; a first moving device for relatively moving said main shaft against a work object; a second moving device for relatively moving said main shaft along the joint line of said work object; a detector for detecting the torque current value of said main shaft when inserting said friction stir welding tool to said work object; and a control unit for correcting the coordinate value of said work object based on the detected value of said detector, and for driving said first moving device based on the corrected value.

3. A friction stir welding method comprising the steps of: detecting the torque current value of a rotation axis of a friction stir welding tool during a friction stir welding process; and controlling the depth of insertion of said friction stir welding tool to a work object based on the detected value.

4. A friction stir welding method comprising the steps of: P:'opcr'es\12555570 Div I oF23101.01 do-24/o1/05 -21- detecting the toque current value of a rotation axis when inserting a friction stir welding tool to a work object; correcting the coordinate value of said work object based on said detected value; and controlling the relative amount of movement of said friction stir welding tool against said work object based on the corrected value.

5. A friction stir welding method comprising the steps of: when inserting a friction stir welding tool to a work object, detecting the current flowing in said tool being transmitted when said tool contacts said work object; correcting the coordinate value of said work object based on said detected value; and controlling the relative amount of movement of said friction stir welding tool against said work object based on the corrected value.

6. A friction stir welding device substantially as hereinbefore described with reference to the accompanying drawings.

7. A friction stir welding method substantially as hereinbefore described with reference to the accompanying drawings. DATED this 31 st day of January, 2005 Hitachi, Ltd. by DAVIES COLLISON CAVE Patent Attorneys for the Applicant