CN102085537A - 摩擦搅拌成形方法 - Google Patents

摩擦搅拌成形方法 Download PDF

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CN102085537A
CN102085537A CN2009103108483A CN200910310848A CN102085537A CN 102085537 A CN102085537 A CN 102085537A CN 2009103108483 A CN2009103108483 A CN 2009103108483A CN 200910310848 A CN200910310848 A CN 200910310848A CN 102085537 A CN102085537 A CN 102085537A
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workpiece
mould
groove
friction stir
manufacturing process
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CN102085537B (zh
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中川考一
刘庆
盐泽勇雄
中川威雄
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Hongfujin Precision Industry Shenzhen Co Ltd
FTC Corp
Hon Hai Precision Industry Co Ltd
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Hongfujin Precision Industry Shenzhen Co Ltd
FTC Corp
Hon Hai Precision Industry Co Ltd
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Priority to CN2009103108483A priority Critical patent/CN102085537B/zh
Priority to US12/750,883 priority patent/US7971770B2/en
Priority to JP2010091523A priority patent/JP5638275B2/ja
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
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    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
    • B23K20/1245—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding characterised by the apparatus
    • B23K20/1255—Tools therefor, e.g. characterised by the shape of the probe
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    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
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    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
    • B23K20/1275—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding involving metallurgical change
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
    • B23K20/128—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding making use of additional material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/06—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding
    • B29C65/0681—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using friction, e.g. spin welding created by a tool
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
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    • B29C65/606—Riveting or staking the rivets being integral with one of the parts to be joined, i.e. staking
    • B29C65/608—Riveting or staking the rivets being integral with one of the parts to be joined, i.e. staking the integral rivets being pushed in blind holes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/124—Tongue and groove joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/12—Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/124—Tongue and groove joints
    • B29C66/1242—Tongue and groove joints comprising interlocking undercuts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/32—Measures for keeping the burr form under control; Avoiding burr formation; Shaping the burr
    • B29C66/322—Providing cavities in the joined article to collect the burr
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/45—Joining of substantially the whole surface of the articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/814—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps
    • B29C66/8141—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined
    • B29C66/81431—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single cavity, e.g. a groove
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    • B23K2101/00—Articles made by soldering, welding or cutting
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    • B23K2103/00—Materials to be soldered, welded or cut
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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)

Abstract

一种摩擦搅拌成形方法，包括以下步骤：提供工具；提供模具，该模具包括表面，该表面上开设有凹槽；提供工件，将所述工件设置模具开设有凹槽的表面上；将工具抵压工件，并在旋转同时沿着凹槽开设的方向移动，将工件的材料局部进行摩擦搅拌，从而于模具凹槽内形成与工件为一体的凸起。所述摩擦搅拌成形方法可轻松成形形状复杂的工件，加工效率较高，且成形时是利用材料的流动，而无需切除材料，故材料利用率高。

Description

摩擦搅拌成形方法
技术领域
本发明涉及一种摩擦搅拌成形方法，特别涉及一种无搅拌针的摩擦搅拌成形方法。
背景技术
在金属或塑料等板材上形成凹凸的方法有以下三种：(1)通过切削等进行部分切除的方法，即切除加工；(2)其它部件或其它材料的接合或层迭的方法，即接合附加加工；(3)沿着模具进行变形加工的方法，即变形加工。其中，切除加工时，虽然形状的自由度高，但其生产效率低；接合附加加工和变形加工时，生产效率虽高，但受到形状的制约，难以加工形状复杂的产品。因此，人们一般根据需要选用适当的方法。
其中，根据板厚的变化进行部分的凹凸形状变化的时候，选用挤压机械与模具，通过压印加工、锻造、半冲压等加工可将模具的凹凸面转印至被加工材料上。但是，在板材上形成部分的凹凸形状的时候，需要与转印面积相比例的加压力，因此通常需要巨大的加压力，从而只适用于小物品上。又因施加部分的变形加工，会在板材上发生对板材整体有害的弯曲变形。如果能解决以上的通过挤压加工在板材上形成凹凸形状的方法中存在的问题，那板材的部分的成形方法的适用范围会大大提高，加工费也削减，材料的利用率也会提高。
也有为了减少加压力而对被加工材的整体进行加热软化的对策，但是基本上是热间挤压成形，因此，不适用于大尺寸的板材的加工。针对这个，也有只对局部加热变形的方法，但是，由于对板材施加局部加热，板材上会发生部分的热膨胀，又通过冷却后的收缩会在板材上残留较大的内部应力，因此板材上会发生弯曲变形。因此，实际上对某种尺寸以上的板材来说，通过挤压变形而形成凹凸形状的方法会出现很多问题。
发明内容
鉴于上述状况，有必要提供一种新的加工效率高、材料利用率高、且能成形复杂形状的成形方法。
一种摩擦搅拌成形方法，包括：提供工具；提供模具，该模具包括表面，该表面上开设有凹槽；提供工件，将所述工件设置模具开设有凹槽的表面上；将工具抵压工件，并在旋转同时沿着凹槽开设的方向移动，将工件的材料局部进行摩擦搅拌，从而于模具凹槽内形成与工件为一体的凸起。
所述摩擦搅拌成形方法可轻松成形形状复杂的工件，加工效率较高，且成形时是利用材料的流动，而无需切除材料，故材料利用率高。
附图说明
图1是本发明实施例所采用的接合工具的结构示意图。
图2是图1所示接合工具的摩擦面的结构示意图。
图3是图1所示接合工具的摩擦面的另一结构示意图。
图4是本发明实施例一采用的模具的结构示意图。
图5是本发明实施例一采用结合工具成型工件的结构示意图。
图6本发明实施例二采用的模具的结构示意图。
图7本发明实施例二的工件成型的状态示意图。
图8本发明实施例二的工件成型的另一状态示意图。
图9本发明实施例二的工件成型的另一状态示意图。
图10本发明实施例二的成型后的工件的结构示意图。
图11本发明实施例三采用的模具的结构示意图。
图12是本发明实施例三采用结合工具成型工件的结构示意图。
具体实施方式
下面将结合附图及具体实施方式对本发明提供的摩擦搅拌成形方法作进一步地详细说明。
请同时参阅图1，本发明实施例的摩擦搅拌成形方法采用工具10进行。请同时参阅图1至图3，工具10基本呈柱状，一端具有摩擦面11，该工具10的摩擦面11一端为平头，即该摩擦面11基本为平面。自该摩擦面11向工具10的内部凹陷形成有若干凹槽13，凹槽13的形状可以为螺旋状或以工具10的回转中心为共同起点的若干条圆弧。工具10工作时的旋转方向与凹槽13自中心向外延伸的方向相同。
请参阅图4，本发明实施例一进行摩擦搅拌成形，还需模具20。该模具20包括表面202，表面202上开设有截面为矩形的凹槽204。该表面202可为平面，也可为曲面，表面202和凹槽204的形状都根据最终产品的预定形状设置。
请参阅图5，需要成形的工件40大体为板状，其包括摩擦面400。进行摩擦搅拌成形时，将工件40放置模具20的表面202上，且使摩擦面400背离模具20的表面202。将工具10抵压工件40的摩擦面400，并在旋转同时沿着凹槽204开设的方向移动，将接合线附近的材料局部进行摩擦搅拌。工件40的材料在摩擦搅拌下产生热量，热量于工件40内部传递，并使其至少部分材料发生塑性流动，从而流入模具20的凹槽204内，从而模具20的凹槽204被工件40的材料充填。这样，工件40对应凹槽204处即形成了所要成形的凸起402，当然，同时工件40的摩擦面400上残留有工具10压入工件40的凹痕。最后，根据需要将工件40摩擦面400表层的部分材料去除，使其表面平整，当然，如果对工件40的摩擦面400的表面要求较低时，也可省略该去除表层材料的步骤。
这种成形方法虽然也适用于较厚的工件，但是在厚度达到一定程度的工件来说，成形过程中工件凹陷量大于模具的凹部体积时，工具的周围会发生材料的隆起，所以有必要时通过后加工可将这些隆起除去。又，将工具10不仅可沿着凹槽204方向移动，还可沿垂直于凹槽204延伸方向的方向或其他方向于摩擦面400上移动，通过这些可将工件40的材料更有效的充填于模具20的凹槽204内。
当工件40的材料无法充分的填充至较深的凹部底面或角部的时候，也可将同种材料或不同种材料的辅料补入到会发生空洞的地方，再次进行摩擦搅拌成形，将工件与上述辅料进行接合的同时成形，具体如下面实施例二所述。
请参阅图6至图10，图中为本发明实施例二的摩擦搅拌成形法。实施例二与实施例一大体相同，其不同在于：实施例二中需要成形于工件上的凸起高度更大。实施例二的摩擦搅拌成形法采用模具50，该模具50上开设有凹槽504，且凹槽504的深度较凹槽204更大。要成形的工件60包括摩擦面600。
成形时，将工件60放置模具50的开设有凹槽504表面上，且使摩擦面600背离模具50的凹槽504。将工具10抵压工件60的摩擦面600，并在旋转同时沿着凹槽504开设的方向移动，将接合线附近的材料局部进行摩擦搅拌。于实施例一类似，工件60的材料发生塑性流动，流入模具50的凹槽504内形成凸起602。然而，由于凹槽504的深度过大，材料无法完全充满凹槽504。接着将辅料70放置于工件60的摩擦面600，再次旋转并移动工具10，将工件60与辅料70进行接合的同时成形，材料完全填满凹槽504形成凸起604。本实施例中，辅料70的材料与工件60相同。这样，工件60对应凹槽504处即形成了所要成形的凸起704。最后，根据需要将工件60摩擦面600表层的部分材料去除，使其表面平整，当然，如果对工件60的摩擦面600的表面要求较低时，也可省略该去除表层材料的步骤。另外，工具10也可于摩擦面600上沿不同方向移动。
请参阅图11及图12，图中为本发明实施例三的摩擦搅拌成形法。本实施例需要模具80及辅料92。模具80上开设有形状复杂的凹槽804，本实施例中，凹槽804为T形。辅料92的形状与凹槽804的形状对应，即辅料92可刚好容纳于凹槽804内。成形时，将工件90放置模具80的开设有凹槽804表面上。将辅料92放置于凹槽804内，将工具10抵压工件60背离凹槽804的表面上，并在旋转同时沿着凹槽804开设的方向移动，将工件90和辅料92的材料局部进行摩擦搅拌。工件90和辅料92的材料发生塑性流动，将工件90和辅料92接合起来，这样工件90上即形成了凸起902。需要时，将工件90表层被摩擦搅拌的材料去除。
工具10的摩擦面11的中心部也可设置有突起，该突起上也设置有螺纹状沟，该突起可将材料往前方送入，以此可有效的充填凹槽204、504。使用的工具10的直径由凹槽204、504的大小及深度而决定，但是不一定非得使用直径比凹槽204、504的尺寸大的工具10，也可使用直径小的工具10反复的进行摩擦搅拌形成所需的形状。
所述工件40、60、90和辅料70、92的材料可以为铝、铝合金、铜合金、橡胶等熔点较低的材料，形状也不局限于固定形状，可以为任何结构。
所述摩擦搅拌成形法具有下述特点：(1)工具10所需的直径可较小，因此所需的加工动力及压力小、设备小、价格便宜；(2)具有可自动交换工具的切削用机械加工中心可直接使用于本加工方法中，并且成形前后在同一装置下可进行切削的预备加工及后处理；(3)可适用于少量生产及多量生产，适用范围广，使用同一种生产设备，可进行多种成形或多种产品变化；(4)是连续或反复进行局部的成形，因此不会发生像挤压加工中所产生的工件整体变形等问题，因此不会破坏工件整体精度；(5)凹槽内所充填的材料不足的时候，成形后将工具退出后，追加新的同种材料片，然后反复进行搅拌工程使追加的材料与母材成为一体，从而使充填于模具凹部内的材料充分，又可成形较大尺寸或高的凸起，十分灵活、方便；(6)如果在模具上形成有微细图案，也可实现微细图案的成形；(7)往凹陷处投入的追加材料片的种类可不同，从而可形成具有多功能的部件；(8)加工效率高，且需要切除的材料较少，材料利用率高。
本领域技术人员还可在本发明精神内做其它变化，当然，这些依据本发明精神所做的变化，都应包含在本发明所要求保护的范围内。

Claims (8)

1.一种摩擦搅拌成形方法，包括：
提供工具；
提供模具，该模具包括表面，该表面上开设有凹槽；
提供工件，将所述工件设置模具开设有凹槽的表面上；
将工具抵压工件，并在旋转同时沿着凹槽开设的方向移动，将工件的材料局部进行摩擦搅拌，从而于模具凹槽内形成与工件为一体的凸起。
2.如权利要求1所述的摩擦搅拌成形方法，其特征在于：所述工件的材料在摩擦搅拌下产生热量，并使工件的至少部分材料发生塑性流动，流入模具的凹槽内，使模具的凹槽被工件的材料充填而形成所述凸起。
3.如权利要求2所述的摩擦搅拌成形方法，其特征在于：所述凸起未填满所述模具的凹槽；进一步提供辅料，将辅料放置于工件相对模具的一侧；工具抵压辅料，并在旋转同时沿着凹槽开设方向移动，将辅料的材料局部进行摩擦搅拌，从而于模具凹槽内形成与工件为一体、且完全填满模具凹槽的凸起。
4.如权利要求3所述的摩擦搅拌成形方法，其特征在于：所述辅料的材料为铝、铝合金、铜合金或橡胶。
5.如权利要求1所述的摩擦搅拌成形方法，其特征在于：进一步提供辅料，该辅料的形状与模具凹槽形状大体对应，于工具进行摩擦搅拌前，将辅料置于模具凹槽内，利用摩擦搅拌将工件和辅料接合为一体。
6.如权利要求5所述的摩擦搅拌成形方法，其特征在于：所述工件的材料为铝、铝合金、铜合金或橡胶。
7.如权利要求1至6任意一项所述的摩擦搅拌成形方法，其特征在于：所述摩擦搅拌成形方法还包括在所述凸起形成后，于所述工件的表层去除一定厚度的材料。
8.如权利要求1所述的摩擦搅拌成形方法，其特征在于：所述工件的材料为铝、铝合金、铜合金或橡胶。
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