A kind of manual stirring rubs welding equipment and method
Technical field
The invention belongs to agitating friction solder technology field, be specifically related to a kind of manual stirring and rub welding equipment and welding procedure thereof, particularly can realize one side welding with back formation, be suitable for the Apparatus and method for of Aluminum-aluminum alloy welding.
Background technology
Friction stir welding (FWS) is the novel solid phase joining technique of one of Britain's institute of welding (TWI) 1991 exploitation, and compared with traditional welding method, it has that welding quality is high, production cost is low and the advantage such as non-environmental-pollution.Since friction stir welding technological invention, be that a welding difficult problem such as slag inclusion, pore, crackle, the strength of joint reduction etc. of the light alloy material of representative are solved effectively with Aluminum-aluminum alloy.In addition to aluminum, the welding difficult problem of Welder author also between the Welding Problems actively utilizing agitating friction welding solution materials with high melting point and dissimilar metal, nowadays these aspects all obtain many achievements.The maximum feature of agitating friction welding technology utilizes stirring-head and soldered intermetallic frictional heat to make welded metal reach plastification, is then uniformly mixed by the metal of plastification and makes it reach by the extruding of stirring the shaft shoulder to combine closely under the drive of mixing needle.From the realization of technical process and prevent mixing needle from reducing the wastage welding process, generally the length dimension of mixing needle is slightly smaller than welded piece thickness, in this case, each agitating friction welding is all difficult to the through welding realizing workpiece, and it is lack of penetration that root always has certain thickness.For addressing this problem, welding by both sides can be adopted or use both shoulders head to weld.Two-weld process and stirring-head structure simply, but need upset workpiece to carry out twice welding.During the welding of both shoulders stirring-head, stirring-head structural design is more complicated, needs to adjust the distance between both shoulders head when different-thickness sheet material welds.This process is cumbersome, and the structure stress relative complex of stirring-head, easily make stirring-head produce fracture failure.Chinese patent 200810202856.1 propose a kind of newly realize one side welding with back formation---piercing welding technique.Be exactly bottom it, padded a thin plate in advance before workpiece welding, thickness is 0.5 ~ 1 ㎜.In welding process, allow stirring-head pass thickness of slab, backing plate is welded on workpiece by agitating friction welding together that be similar to lap joint.Because backing plate is thinner, postwelding backing plate both can be removed, and also can retain and all can not produce larger impact to structure.But from construction profile, not still optimum.
So far, under agitating friction welding technology is still in patent protection, agitating friction welding machine special equipment is huge, and be generally all designed to the relatively high equipment of automatization level both at home and abroad, therefore its price is very high.It is reported its domestic price generally more than 1,000,000 yuan, and some less scientific researches, educational institution and enterprises and institutions just can only be too far behind to catch up.In addition, from the angle of the training of personnel, manual operations is the basis of carrying out automation mechanized operation, and basic manual operations can help the impact understood and comprehension welding parameter butt welded seam is shaped to have very dark meaning.Therefore, can say that agitating friction soldering equipment that automaticity is high is not necessarily applicable to for the personnel of original learning agitating friction welding technology.Therefore, the scientific research required for general no special, teaching are studied carefully mechanism and can be realized agitating friction basic function, and the simplified manual welding machine meeting the super quality and competitive price of basic welding quality requirement more can satisfy the demands.
Summary of the invention
The object of this invention is to provide a kind of agitating friction welding equipment and welding technique of manual Aluminum-aluminum alloy, can one side welding with back formation be realized, prevent from applying adhesion to the weldering of back of work backing plate, meet the demand of teachings and researches.
The technical solution used in the present invention is: a kind of manual stirring rubs that welding equipment comprises rigid support platform, support platform moves gripping mechanism, workpiece grip mechanism and friction-stir head, work piece is on rigid support platform, friction-stir head has bare terminal end, the shaft shoulder and mixing needle, mixing needle of the present invention is the stepped cylindrical shape of retracted downward step by step, and mixing needle bottom center has hemisphere jut.Below workpiece, have steel cushion plate, steel cushion plate upper central has the two stage steps groove corresponding with weld seam, and two stage steps groove is placed with in notch and the liner of workpiece with material, liner thickness is 0.5 ~ 1mm.On workpiece, seam both sides are fixed with two guide groove plates, the spacing of two guide groove plates and the shaft shoulder equal diameters of stirring-head.
Manual stirring welding method of rubbing is installed to by pin by steel cushion plate to have on the rigid support platform at angle of inclination; The rigid support platform installed is placed into jaw and is fixedly clamped, using high one end as initiating terminal, low one end is as end end; Be that the liner of 0.5 ~ 1 ㎜ is placed in the groove of steel cushion plate by preprepared thickness; Alignment pieces, keep seam to be in the centre position of liner; Install at workpiece surface and place guide groove plate; Be clamped on rigid support platform with four locking pliers by workpiece, guide groove plate, rigid support platform is fixed in cross mobile platform jaw; Adjustment stirring-head position, makes stirring-head enter smoothly in gathering sill, can move to final position from original position; Adjustment stirring-head height, adjustment travelling workpiece clamping feed mechanism, makes stirring-head shaft shoulder height can arrive about 0.5mm under the surface of the work welding final position; Starter motor, welding, slowly sends stirring-head to after electric motor starting; After stirring-head and test piece for welding contact friction, apply certain downforce, stirring-head friction is made to slip into spin friction heating in workpiece, when the aqueous vapor of surface of the work absorption is because of heating explosive vaporization, start to shake rotary handle to carry out cross mobile platform and move, start hourly velocity slightly slow, when keeping evenly after quickening translational speed to predetermined speed of welding suitable after weld seam is formed; When being welded to end position, stopping shake mobile platform, slowly lift stirring-head, press motor shutdown switch.Finally unclamp four locking pliers, unclamp mobile platform jaw, pull down guide groove plate and workpiece.
The present invention penetrates Forming Theory according to back side aperture, in stir friction welding process, utilizes the minor diameter termination of mixing needle tip designs to penetrate the test piece for welding seam back side and forms aperture, thus ensure root through welding.It is the mixing needle tip designs one section of minor diameter termination at stirring-head.When one side welding with back formation welds, the process utilizing minor diameter mixing needle termination to penetrate workpiece formation aperture combines with steel cushion plate, both ensure that penetrating of workpiece, has additionally reduced the friction-stir process to back side backing plate, prevented both welderings to apply adhesion.
The present invention is a kind of multilayer single track welding manner, and its object is exactly to realize the agitating friction welding effect the same with means of fusion arc welding, and thick plates is carried out layering welding.This is a kind of brand-new process realizing the welding of cut deal agitating friction.In welding process, will treat that workpiece carries out layering single track in a thickness direction and welds, to realize the difference of weld width and present situation on different-thickness, thus realize the optimization of property of welded joint.The realization of this welding manner depends on the stepped cylindrical shape stirring-head of the retracted downward step by step of particular design.As everyone knows, stir when rubbing welding, the diameter of mixing needle and length become certain and associate with thickness of workpiece.For heavy thickness workpiece, be to meet the force request of welding process to mixing needle according to minor diameter mixing needle.Stressed from mixing needle, the root of mixing needle is subject to maximum stress loading, and therefore, the greatest danger point also herein.For preventing mixing needle to lose efficacy at fracture of root, require that the diameter of mixing needle is along with the thickness proportion of plate increases.The mixing needle friction main part of stirring-head designed by the present invention is the stepped cylindrical shape of retracted downward step by step.Its main purpose is the layering single-run welding realizing Welding Process based on Medium Plate.
The stirring-head that traditional agitating friction welds by the present invention changes segmentation multiple stage rank friction mode of heating into primarily of shaft shoulder friction heating of metal, mixing needle is utilized to stir at the plastification metal that the step end face of diverse location and the friction between column side face and weld metal and its cause the metal that heat that flowing produces heats each aspect, in welding process, each step surface of mixing needle and the weld metal of relevant position have enough large contact, therefore, fricative heat is relatively more and also stronger to the stirring action of plastification metal, thus makes metal preheating faster.Therefore, Temperature Distribution is in a thickness direction relatively closer to evenly.The stepped cylindrical shape stirring-head of retracted downward is when initial friction step by step, because mixing needle point diameter is comparatively thin, when with soldered Metal Contact, improve lower compression, easily make stirring-head be pressed into metal inside, improve initial generation of stirring heat, accelerate the plastification process of metal.Mixing needle point diameter is less, can reduce the bending moment that in stirring movement process, plastic metal produces mixing needle, thus improves the stress state between stirring-head and the shaft shoulder.
There is certain concave shape in the step planes at different levels of the stepped cylindrical shape mixing needle of retracted downward step by step, and the metal of step surface to plastification of indent forms certain downforce, has tamped weld metal.The step progression of mixing needle can be determined according to institute's welding plate is thick, and the thicker progression of plate is more.The diameter of cylinder at different levels and length will be determined through analog simulation optimization according to stress state suffered by mixing needle.Step foremost mainly plays the effect ensureing to penetrate back of work in welding process, and its length is 0.5 ~ 1mm, and diameter is 2.5 ~ 3mm.The stepped cylindrical shape stirring-head of retracted downward can carry out structure according to the requirement difference of wearability and use particular design and the manufacture of material step by step.
The adhesion technology of the thin backing plate of back of work.For preventing back of work welding with backing from linking on workpiece, the weldering amount of applying of weldment and back side backing plate can be made to minimize, and adoptable measure has as far as possible, and (1) reduces mixing needle diameter, and the weldering of minimizing weldment and back side backing plate is applied and measured; (2) become semicircle spherical mixing needle end machining, reduce mixing needle by together with being stirred to backing plate metal bottom workpiece.(3) reduce the rigidity of back side backing plate, utilize mixing needle the workpiece bottom metal of its near zone and backing plate metal separation to be opened as much as possible.The present invention devises friction stir welding one side welding with back formation special steel cushion plate, utilizes the flexibility characteristics of cushion plate, solves the adhesion problems of one side welding with back formation back side backing plate.
The inventive method is simple and practical, can realize high-quality welding.Devices with low cost drops into, and is easy to make, and has effect of imparting knowledge to students preferably.
Accompanying drawing explanation
Fig. 1 is the single face welding and double face shaping friction stir welding schematic diagram of existing employing backing plate, and wherein 3 is mixing needle, and 6,8 is left and right workpiece, and 4 is the thin liner of same material, and 10 is steel cushion plate;
Fig. 2 is stirring-head structural representation of the present invention, and wherein 1 is stirring-head bare terminal end, and 2 is the shaft shoulder, and 3 is mixing needle, and stirring-head total length is L, and bare terminal end length is L1, and diameter is D1, and shaft shoulder height is L2, and diameter is D2;
Fig. 3 is the partial enlarged drawing of Fig. 2, and mixing needle is made up of three grades of cylinder steps, and first order height is L3, and diameter is D3, and second level height is L4, and diameter is D4, and the third level is highly L5, and diameter is D5, and bottom surface hemisphere jut height is 0.5 ~ 1mm, and diameter is D6;
Fig. 4 is the structural representation of steel cushion plate, and the height of steel cushion plate is H1, and width is B1, has second recess above, and first recess height is H2, and width is B2, and second recess height is H3, is highly B3;
Fig. 5 is the single face welding and double face shaping friction stir welding schematic diagram of Aluminum-aluminum alloy of the present invention, and wherein 1 is stirring-head bare terminal end, and 2 is the stirring-head shaft shoulder, 3 is mixing needle, 4 is the thin liner of same material, and 5 is guide groove plate, and 6 is workpiece I, 7 is prearrangement of deformation amount space, 8 is workpiece II, and 9 is pin, and 10 is steel cushion plate, 11 is support platform, and 12 is cross mobile platform jaw.
Detailed description of the invention
Embodiment utilizes the system reform of common desktop drilling machine to become Mini-sized manual agitating friction to weld equipment, and the small-scale research and the elementary student that are well suited for the relevant departments such as middle-size and small-size enterprises and institutions, institution of higher education learn agitating friction technology.Hand operated mixing friction welding (FW) one side welding with back formation is on the basis of bench drill, power of motor is enlarged to more than 2KW, rigid support platform 11 table top installs cross and moves flat pliers mouth 12, utilize special stirring head of the present invention, guide groove plate 5, steel cushion plate 10 and have 3 ~ 5 ° of gradients rigid support platform 11 with the use of having come.
Bare terminal end 1 diameter of stirring-head and be highly D1, L1, the diameter takeing on axle 2 be highly D2, L2; Mixing needle 3 is three grades of cylinders, from top to bottom cylinder at different levels diameter and be highly respectively D3, L3, D4, L4, D5, L5, the ball bumps diameter of mixing needle bottom center is D6; Close between the physical dimension of stirring-head and the thickness t of workpiece and be: D2=2 ~ 3t, D3=0.8 ~ 1t, D4=k × D3, D5=k × D4, wherein: k=1/2 ~ 2/3, when welding for low-intensity material, k removes the limit, during high-strength material welding, and k capping; L3=1/2t; L4=1/3t; L5=1/6t; The height of bottom center's ball bumps of mixing needle is 0.5 ~ 1mm.Selecting of stirring-head material has diversity, and retained part can select high-strength steel, as middle carbon quenched and tempered steel.The shaft shoulder and mixing needle part part can select heat resistance strong, have the high-alloy steel of some strength, as wolfram steel, high-speed steel etc.Mixing needle two part can select the carbide alloy such as high-alloy steel or carbide of hard high-wearing feature, as high-speed steel, boron nitride etc.Stirring-head can form through Quenching Treatment according to design bar time processing, forms after bi-material also can be adopted to process respectively through combination installation.
Stirring-head is that two incorporating aspects (or more incorporating aspects, depend on the size of mixing needle) are formed, and adopts and be fixedly connected with or be flexibly connected between two incorporating aspects, is fixedly connected as welding or interference fit connects, and movable connection method is that left-hand thread connects.Left-hand thread connects can carry out length adjustment according to thickness of workpiece, has thickness adaptability well.
The upper well width of steel cushion plate 10 two stage steps groove is B2, and the degree of depth is H2, and lower well width is B3, and the degree of depth is H3, and the physical dimension of two stage steps groove and the pass of mixing needle are: B2=2 × D3, B3=(1.5 ~ 2) × D6, H2=H3=0.5 ~ 1mm.Rigid support platform 11 has the angle of inclination of 3 ~ 5 °.Keep concordant with steel cushion plate 10 by being placed into after in the stepped recesses of steel cushion plate 10 with the liner 4 of material with workpiece.When mixing needle 3 is depressed into after on liner 4 through weldment, due to the thin and bottom preset clearance 7 of liner 4, make it have living space and be out of shape, which reduces the soldered possibility to back of work.
Welding operation process:
1, cross mobile platform jaw 12 is installed on rigid support platform 1.
2, steel cushion plate 10 is installed to by pin 9 has on the rigid support platform 10 at angle of inclination.
3, the rigid support platform 11 installed be placed into cross mobile platform jaw 12 and clamp fixing, using high one end as initiating terminal, low one end is as end end.
4, be that the aluminium backing plate 4 of 0.5 ~ 1 ㎜ is placed in the two stage steps notch of steel cushion plate 10 by preprepared thickness.
5, aim at installation workpiece 6,8, seam be kept to be in the centre position of rigidity cushion board slot 10.
6, at workpiece surface, placement guide groove plate 5 is installed, requires that two guide groove plate 5 center lines align with workpiece 6,8 seam.
7, fixation workpiece 6,8 and guide groove plate 5, utilize four locking pliers by workpiece 6,8, guide groove plate 5 is clamped on rigid support platform 10.
8, adjusting stirring-head position makes it enter smoothly in guide groove plate 5, and can successfully realize moving to final position from original position.
9, stirring-head height is adjusted.Adjustment drilling machine feed mechanism, makes the stirring-head shaft shoulder 2 height can arrive the surface of the work of welding final position.
10, weld, starter motor, slowly sends stirring-head to after electric motor starting.
11, after stirring-head and workpiece 6,8 contact friction, apply certain downforce, spin friction heating in workpiece is slipped in stirring-head friction, when workpiece 6,8 adsorption aqueous vapor is because of heating explosive vaporization, start to shake rotary handle to carry out cross mobile platform and move, it is slightly slow to start hourly velocity.When keeping evenly after quickening translational speed to predetermined speed of welding suitable after weld seam is formed.
When 12, being welded to end position, stopping shake mobile platform, slowly lift stirring-head, press motor shutdown switch.Unclamp four locking pliers, unclamp mobile platform jaw, pull down guide groove plate 5 and workpiece 6,8.