CN1167024A - 摩擦搅动焊接的改进 - Google Patents

摩擦搅动焊接的改进 Download PDF

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CN1167024A
CN1167024A CN97113489A CN97113489A CN1167024A CN 1167024 A CN1167024 A CN 1167024A CN 97113489 A CN97113489 A CN 97113489A CN 97113489 A CN97113489 A CN 97113489A CN 1167024 A CN1167024 A CN 1167024A
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rotatable parts
cutting insert
cutting
improvement
cutting blade
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CN1084655C (zh
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凯文·J·科利根
史蒂文·J·阿维拉
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Boeing Co
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    • 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
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114—Single butt joints
    • B29C66/1142—Single butt to butt joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C5/00—Milling-cutters
    • B23C5/16—Milling-cutters characterised by physical features other than shape
    • B23C5/20—Milling-cutters characterised by physical features other than shape with removable cutter bits or teeth or cutting inserts
    • B23C5/22—Securing arrangements for bits or teeth or cutting inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • 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
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • 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
    • B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
    • B23K37/08—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups for flash removal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B29C37/02—Deburring or deflashing
    • B29C37/04—Deburring or deflashing of welded articles, e.g. deburring or deflashing in combination with welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • 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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    • B29C66/14—Particular design of joint configurations particular design of the joint cross-sections the joint having the same thickness as the thickness of the parts to be joined
    • 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
    • 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
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • 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
    • B29C66/70—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
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    • B29C66/739—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 intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—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 intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—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 intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • 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
    • B29C66/80—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
    • B29C66/81427—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 ridge, e.g. for making a weakening line; comprising a single tooth
    • B29C66/81429—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 ridge, e.g. for making a weakening line; comprising a single tooth comprising a single tooth
    • 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
    • B29C66/80—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
    • B29C66/818—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 cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps
    • B29C66/8181—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 cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the cooling constructional aspects
    • B29C66/81811—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 cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the cooling constructional aspects of the welding jaws
    • B29C66/81812—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 cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the cooling constructional aspects of the welding jaws the welding jaws being cooled from the outside, e.g. by blowing a gas or spraying a liquid
    • 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
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/836—Moving relative to and tangentially to the parts to be joined, e.g. transversely to the displacement of the parts to be joined, e.g. using a X-Y table
    • 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
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
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    • 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
    • B29C66/81411—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 characterised by its cross-section, e.g. transversal or longitudinal, being non-flat
    • B29C66/81421—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 characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being convex or concave
    • B29C66/81422—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 characterised by its cross-section, e.g. transversal or longitudinal, being non-flat being convex or concave being convex
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/51—Plural diverse manufacturing apparatus including means for metal shaping or assembling
    • Y10T29/5147—Plural diverse manufacturing apparatus including means for metal shaping or assembling including composite tool
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
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Abstract

对于有一个转动部件的摩擦搅动焊接工具的改进包括一个附装的切削刀具，其有一个或多个切削刀刃。此外，提出了改进摩擦搅动焊接的方法，其包括：在传统的摩擦搅动焊接工具上安装一个有切削刀刃的切削刀具；在进行焊接时，在切削刀刃上加液体，以使切削刀刃的表面很快冷却，而使材料不会粘结到切削刀刃上，使切削刀具将多余的焊接材料加工掉。

Description

摩擦搅动焊接的改进
本发明涉及摩擦焊接，特别是加工摩擦搅动焊缝的设备和方法。
摩擦搅动焊接(FSW)是由英国剑桥的焊接学院(TWI)发明并取得专利的一种较新的焊接方法。关于这种焊接法及完成它的设备的详细的描述见专利WO 93/10935、美国专利5,460,317及WO 95/26254。在FSW法中，使用一个非自耗性的转动焊具来沿对接的接头“搅动”金属。这样使得对接接头两边的金属完全地融合。
在焊接之后，必须为那些要求一个平滑的接头外表面的应用场合(例如疲劳负荷的组件、气动力学的表面、精密接触啮合等)加工焊缝的上表面。加工焊件接头处也有助于检查焊接接头的裂纹、伤痕等。由于FSW通常在一个传统的铣床上完成，可以把对焊缝的加工作为第二道工序。但是，由于它比那些不需要一个加工的表面的用途要花双倍的时间和努力来获得一加工零件，这使此法增加了可观的成本来生成一个成品。
此外，预料将来的FSW机器，当它们为了作特殊目的的焊接而作了改进后变得不大像铣床。在这种情况下，可能难以用同一台机器来完成焊接和加工焊缝表面，这意味着整个的过程要增加刀具加工成本及装和卸的时间。
因而，需要一种设备及方法以加工一个摩擦搅动焊缝的表面而不需要进行第二道工序或用第二台机器。本发明就是为了满足这种需要。
根据本发明的一个方面，对摩擦搅动焊接工具提供了一个改进，包括一种切削刀具，其有一个或多个径向的切削刀刃。此切削刀具通过一个或多个支持装置安装在一个传统的移动摩擦搅动焊接工具上，因而在焊接时，改进了的焊接工具将对焊缝作加工。优选的切削刀具包括一个或多个可卸下的支持装置，例如刀削插入物，附装在摩擦搅动焊接的转动部件上。每个支持装置包括一个较低端，其上有一个切削刃或附装其上或与之形成一整体。优选的切削刀刃可以从转动部件上卸下来。当转动部件转动时，切削刀刃也转动，以清除探头及转动部件上的干扰物。
根据本发明的其它方面提供的切削刀具的第一个实例包括一个或多个切削插入物，每个有与之形成整体的较低端的刀刃；在转动部件上有同样数量的垂直方向的供插入配合的凹槽；一个卡圈，其尺寸可紧紧地安装在装有配合插入物的转动部件上；一个卡圈附件使卡圈紧固在转动部件上；以及一些固定螺钉将切削插入物装在转动部件上。卡圈上可以有多种带螺纹的径向孔，其位置相应于切削插入物及凹槽的位置。这些孔用于安装固定螺钉以压紧切削插入物并防止切削插入物在使用时移动。优选的卡圈包括在紧挨着每个切削插入物处的内切口。
根据本发明的另一些方面提供的切削刀具的第二个实例包括：切削插入物的柄的孔，延伸穿过转动部件，与转动部件转动轴成一个角度A；可插入此插入物柄孔的切削插入物的柄；在转动部件上有螺纹的径向的孔；以及一个单螺钉，其旋入该径向孔以使切削插入物的柄紧固在适当的地方。切削插入物柄包括一个有角的切削插入物，其可卸地附装在切削插入物的柄的下端。有角的切削插入物包括一个或多个伸出的角，其可以用作切削刀刃。当一个角变钝时，可转动此带角的切削插入物，一个新的角可以用作切削。提供了将带角的切削插入物紧固到该切削插入物柄上去的装置。
根据本发明的另一些方面提供的切削刀具的第三个实例包括从转动部件的下端径向伸出的一个或多个小翼。这些小翼可以用传统的方法如焊接或铸造等法连接到转动部件上成为整体。每个小翼上可卸地连接一个带角的切削插入物，使一个角延伸到低于小翼的最低点。当角随着转动部件转动时，该角清除焊接表面的残屑。
根据本发明的又一些方面，该切削刀刃优选设置在靠近转动部件的下面周边，其深度大约是相对于转动部件的肩的0.002至0.010英寸，距转动部件的外面和/或其低面的距离约为0.050至0.100英寸。如果可能的话，每个切削刀刃位于相对于转动部件的转动的相应的支撑件的前缘。
根据本发明的又一些方面，对摩擦搅动焊接方法提供了一个改进，包括在传统的摩擦搅动焊接工具上连接一个有切削刃的切削刀具，在焊接时对切削刃提供液体，以使切削刀具很快冷却下来，以防止焊接物粘附在切削刀具上。
根据本发明的又一些方面，一个优选的工艺包括供给水，其温度约为室温(例如10至30℃)，流速为每分钟大约0.01至0.10加仑，呈一种水气雾的方式，水可以在压力下送出。
根据本发明的其它一些方面，转动部件连同其相应的切削刀具和探头，相对于探头直线移动的方向有一个稍稍向后的角度。
在下面参考附图对本发明的详细描述之后，将可更好地理解本发明，更便于评价本发明的前述各个方面及其许多优点。其中：
图1是说明摩擦搅动焊接的第一种方法的等轴视图；
图2A及2B是两种不同的转动部件的立侧视图；
图3是说明引入-引出板的透视图；
图4是平面图，说明塑化物质的流动及接合线处所产生的结果表面标记；
图5A、5B及5C分别是摩擦搅动焊接的第二个例子的等轴视图、侧视图、平面图；
图6A、6B及6C显示用于图5A-5C方法的不同类型的探头形状；
图7是焊接平板的上面及下面都产生焊道的进一步方法的图解；
图8是根据本发明的切削刀具的第一个实施例的等轴视图；
图9是图8的切削刀具的侧视图；
图10是图8的底部仰视图；
图11是根据本发明的切削刀具的第二实施例的等轴视图；
图12是图11切削刀具的侧视图；
图13是图11的切削刀具的底部仰视图；
图14是根据本发明的切削刀具的第三实施例的等轴视图；
图15是图14的切削刀具的侧视图；以及
图16是图14的切削刀具的底部仰视图。
下面首先讨论前述诸专利中的摩擦搅动焊接方法及设备。在专利WO93/10935，美国专利5,460,317及WO 95/26254中描述的摩擦搅动焊接工具及技术与本发明相一致的部分合并在参考文献中，随后是本发明的切削刀具改进设备及方法的详细描述。
将工件连接起来的摩擦搅动焊接技术产生一个工件之间的结合区域，其包括的步骤为：使一个比工件材料更硬的材料制的探头进入接头区域以及在接头区域两边的工件的对立部分的一个或两个部分，同时在探头与工件之间进行相对循环运动，由此产生摩擦热，造成对立部分的塑化状态；移开此探头，例如将探头沿接头区域移动；使塑化部分凝固而使工件连接在一起。这种技术使很多种类的工件能连接起来，工件材料可以是金属、合金或复合材料，例如金属基复合材料(MMC)或合适的塑料如热塑性塑料。
本发明的切削刀具改进实际上可以用于任何具有一个非自耗性的探头的摩擦搅动焊接工具，图1所示是这种焊具的一个透视图。一对工件，平板1A和1B(例如铝合金板)被沿对接线2对接在一起，一个带有一个位于上部和下部5，6之间的狭窄的中心筒状的尖头4的非自耗性的探头3(例如钢探头)被放在对接线2的一端的开始处，部件5、6的近端都有一个肩10及面11。工件在焊接时通常不互相靠近，而是在探头通过时受限制不从对接区域挪开。
带着探头3的转动部件5是用马达7转动的，与此同时，焊接是沿对接线2的标号8的方向横过，同时将平板保持不从探头3的侧向离开。转动的探头3产生摩擦热，在钢尖头4的周围产生局部的高度塑化材料区，而由部件5和6提供上部和底部的约束力。在探头移开或通过后，这些塑化的搅动的区域会立即凝聚并固化。冷却后，塑化材料使工件1A和1B结合在一起，此方法一般是将两个对接的表面的混合，通常混合的温度低于焊接材料的正常熔点。优选使带探头的转动部件5相对于沿着探头移动的直线方向稍稍向后斜置。探头的斜置有助于使肩及部分面与焊接面接触，这样又有利于帮助区域塑化。必须注意部件5和6也贴近接头，以使所述面和肩助于防止塑化区域的材料损失。
另外，上面部件和下面部件5和6及探头3可以合制成一个单独转动部件，或称鼓轮，如图2A所示。在面5A与6A之间，最好预置一个缝隙，约为3.3mm。如图2B所示，该鼓轮可以拆下成两部件5和6′，用例如一个扁销9紧固在一起。按此种安排，可很方便地在要焊接的对接板上按内部件6′的直径钻一个孔，鼓轮的5和6′两部件可以在转动之前牢固地在平板上靠在一起。而且，可以用一个合适的凸轮杆或偏心轮(图上未示)在一个短距离间调整缝隙，以调节要焊接的板的厚度偏离一般值。此外，鼓轮的组成部件上可加以合适的弹性载荷，以便互相偏压，使得即使板的厚度有小的变动时仍能维持紧密贴合。
在这里所描述的每种方法中，为了避免在要焊接的对接板上预钻孔，可以用合适的引入板12及引出板14的延伸，这些延伸或称末端接头，提供了随后将被割掉的焊缝的起点和终点。同样，一个垫圈形的小片(其所用材料与所要焊接的板的成分相似)可以紧固在转动部件的焊杆周围，压向要焊接的板的开始端。当形成塑化材料时，材料可逃逸的空间极小，在焊接的焊缝的全长形成一个均匀的区域。
鼓轮的对接面5A，6A的肩可以制成基本为方形，但优选有一个凹槽(见图2A)。在使用时，在相对于面的直径的宽度的可看见的搅动区域，可以观察到上部和底部的面是否与要焊接的材料接触良好。另一方法，特别是对于弹性载荷型的，所述面可以稍为拱起，其半径的数量级可以为0.1m或再大些，如此则与所用的弹性载荷相对应的接触区域可以具有足够的宽度。此接触区域的宽度优选大于产生塑化物质的焊杆的直径至少50％或更大。
用如所述的合适的鼓轮，转动部件可以被拉着沿对接线2通过一个槽(未图示)，由此使转动部件按照要焊接的物质的表面形状浮动。对于一个用合适的夹具夹住的预先加工的工件，就不需要一个浮动的构件而可以用一个预先设定的鼓轮。
在一个例子中用前述的由两部件组成的鼓轮，摩擦搅动焊接曾被用来成功地焊接一个铝硅镁合金(BS6082)，标定的厚度为3.2mm。相对于所用的有槽的鼓轮的接触区域，热影响区域的总宽度约为9mm。在此例子中，一个直径为6mm的焊杆以1500rpm(圆周速度约为0.47米/秒)转动，同时沿对接线以每分钟370mm通过。应注意的是鼓轮的接触面提供了热输入，转动的焊杆及相应的塑化区域也提供热量。在较低的转动速度下，移动速度也应降低为好，例如，在800rpm时，合适的移动速度约为每分钟190mm。移动速度过大引起发生孔隙或者塑化材料固结不够。
如图4所示，塑化物质被扫至转动探头4的周围，这样，如有孔隙，其将会在转动表面的移动与沿对接线的移动同一方向(前进边)的那一边形成。在其他区域，特别是在转动表面与鼓轮移动通过材料的方向相反(后退边)的那边，塑化的材料充满焊接区域，基本上没有困难得到完全的固结。
图5A及5B显示了摩擦搅动焊接的第二个例子，所述非自耗性的部件上在其前端有一个稍带锥形的筒状探头18，它被压插入板1A、1B之间，但并未延伸到要焊接的材料的全部厚度。因为该探头实际上并不延伸至穿过平板的全部厚度，那就不需要一个下面的部件。较为可取的是使带探头的转动部件相对于探头线性移动的方向稍稍向后斜置。在对焊操作后，平板的上表面的外观见图5A及5C。
在所有情况下，探头的形状是重要的。一个锥形的探头(图6A)使之进入平板相对地容易些，但是其结果是在探头的尖峰附近塑化区域变窄。一个平截头的圆锥体如图6B所示，如果在要焊接的对接平板上预先钻了凹陷，将可工作得最好，较可取的是如图6C所示，探头是稍具锥形的圆筒，形成一个钝鼻子。如前所述，这种形状使探头能压向平板而插进平板中去，在沿着接缝移动的探头的周围形成塑化区域。
用图5A至5C所示的方法焊接6mm厚的铝合金板时，探头可以以850rpm的速度转动，沿对接线以每分钟240mm的速度移动。若用较高的转动速度，例如1000rpm，可以用高些的移动速度，可高至每分钟300mm，但是过分增加移动速度导致在一边形成气孔，如图1用平行边安排所发现的那样。或者，转动速度降至300rpm，同时相应地降低移动速度。对于一个给定的移动速度，可接受的转动速度有一个合理的范围，例如，为焊接铝硅镁合金(BS6082)时，在每秒4mm(每分钟240mm)时，用440至850rpm的转动速度可得满意的结果。
图7显示又一个摩擦搅动焊接方法的实例，其中一对非自耗性的探头20，21与探头18相似，设置在平板1A及1B的相对两边。探头20和21互相相对靠近，但是在移动的方向被位移，如此则平板在合适的位置被夹紧在一起，但还不足以在平板的外向表面与非自耗性部件之间的接触面引起过量的热。一般在摩擦搅动焊接中希望将部件推向平板一定程度以产生所需要的热来完成焊接。但是，不希望过分的推力。平板不应被推得过分而被压坏。或者，图5A至5C的方法可以在要焊接的板的每一面作为单独的操作来实施。按上述方法的一个成功的双面焊的例子是焊接铝硅镁合金，操作的条件是每一面移动速度每分钟240mm，850rpm。
部件23，24的各接触面22可以是大致呈方形的，或者优选稍有槽沟，以缓解其外侧的边。通过观察与平板接触的面所形成的在受扰的平板表面物质的薄且宽的层可以决定合适的转动探头的载荷或固定。或者，转动部件的所述面可以稍为拱起，类似图2A和2B中的鼓轮的表面，由此，在一个给定的载荷下，表面接触面积扩展至至少比探头本身的直径大50％。发现探头直径三倍的接触区域是满意的。对于较薄的材料，优选调整探头尺寸，例如可使之降至4或3mm。未预料到的是，优选的转速也随直径较小的探头的移动速度降低了。例如，一个直径为3.3mm的探头转动速度约为440rpm，移动速度约为每分钟120mm，是较为满意的。在所有情况下，转动部件的面22的轻微锥度约为2°。
图1、5A及7所述的方法可以应用于在给定的材料或基底中有裂纹的对接面以修补裂纹。裂纹可能延伸至整个材料的厚度或者仅穿过材料的部分厚度，可能位于母材或在材料的热影响区，例如紧挨着焊缝或就在焊缝中。图5A的方法一般适合于部分穿过的裂纹，虽然原则上，一个用于完全穿透的裂纹的方法也可用于部分穿过的裂纹。这种技术基本上与前面已描述过的相似，较为可取的是使探头在沿裂纹的接触面移动之前插入母材中(至少插到裂纹的深度)，以便由摩擦热产生塑化材料，在冷却时在原裂纹处固结。移动方向的裂纹的末端可以用各种方法固结。例如，探头可以留在原位，或者以反方向产生焊道并覆盖原焊道，这样反方向焊道终端位于离开原裂纹位置的区域。
当平板被按照前述摩擦搅动焊接法焊接时，多余的变得粗糙的材料倾向于积聚在平板的外表面上。虽然多余的材料的量一般较少，但对于那些要求一个光滑的外表面的用途，多余的材料必须清除掉。如图8至16显示，本发明包括一个切削刀具30，通过在一个常用的移动的摩擦搅动焊接工具上装配一个或多个切削刀刃32而组装成，由此，改进了的焊具将可在焊道产生的同时进行加工。本发明切削刀具加工方法包括在焊接时，向切削刀具及焊缝上施用水或水雾，以使切削刀刃很快冷却，防止材料粘在上面。在FSW工具上增加切削刀刃以及在FSW过程中使用冷却水，其结果可以在焊缝产生的同时得到一个经过精修加工的焊接面。由此，本发明的切削刀具及方法减少了为生产一个经恰当加工的摩擦搅动焊缝的步骤。
切削刀具30主要包括在传统的转动部件38上安装切削刀刃32。一个或多个支持装置被用来在转动部件的外面较低周边附近安装切削刀刃。每一个支持装置包括一个较低端，切削刀刃或者与其构成整体或附装上去。优选切削刀刃用于会引起焊缝表面干扰的传统的摩擦搅动焊接工具的转动部件上。例如，图2B的鼓轮安排优选包括同时位于转动部件5及6′上的切削刀具。也优选每个切削刀刃可以某种形式从转动部件上卸下，这样用旧了的切削刀刃可以容易地用新刀刃更换。本发明的刀削刀具中切削刀刃与转动部件成为整体，虽然此种安排不是很好。
支持装置相对于转动部件的位置应使每个切削刀刃离转动部件中心的径向距离等于或大于预期在焊接时产生的表面干扰的宽度。这一般意味着切削刀刃应被置于正好在面10和/或者肩11区域的外面。切削刀刃位置的高度等于将完成的焊缝面的期望高度。当部件38转动时，切削刀刃32也转动，清除被转动部件探头40干扰的物质。当整个探头沿焊缝2移动时，由切削刀刃界定的圆周也在移动，这样使堆积层被从整个焊接区域清除。其结果产生一个平滑的抛光加工的焊缝。
应用本发明的基本方法包括使切削刀具30装配到转动部件38上，并从液体源82向焊缝2连续供水，同时沿此焊缝转动和移动探头40。在此优选实施例中，水的形式是水和气雾混和物84。较好的水温约为室温，即大约20℃，其流量约为每分钟0.01至0.1加仑，水可以在压力下放出，而且直接加到切削刀刃与材料接触的区域或对接处。用水的重要方面在于它足够用来冷却切削刀刃的外部表面。应当注意的是优选用水因为它损耗量大。其他的液态冷却剂如果不干扰焊缝的形成也可使用。从此焊接过程中流出的水在去掉了焊件加工中积累的金属颗粒后可以循环使用。
关于现行的FSW法，本发明的切削刀具的探头方法的优选实施例包括斜置带探头的转动部件，使其相对于探头线性移动的方向稍稍向后。当加上切削刀刃时，它们主要是从转动部件的拉拽的肩后面加工去掉表面的物质。其结果是从焊缝上去掉最少量的物质而留下一个平滑的工件焊接表面。如果可能的话，引入板12及引出板14伸出部分优选被用于接头提供一个起始点和停止点，见图3。这些伸出部分可以作为单独的部分加到接头上，也可以与要焊接的平板中的一块或同时与两块构成整体，一待焊接完成时，将伸出部分割掉，在焊缝的全部长度上留下一个恰当加工的连续的表面。
在此描述3个优选的切削刀具实施例，图8-10指第一个实施例，图11-13是第2个实施例，图14-16，是第三个。
图8显示的是一个根据本发明形成的切削刀具的第一个实施例的透视图。其支持装置包括一个或多个切削插入物42，每一个有一个低端的切削刀刃；在转动部件38的外围有同样数目的竖向的与插入物配合的槽沟或键槽44；一个卡圈46，其大小可紧围着附装着配合插入物的转动部件；一个卡圈附件，以使卡圈紧固于转动部件上；以及一些固定螺钉48，以使插入物42固定在转动部件38上。
切削插入物42通常截面是矩形的，具有圆的较低端切削刀刃。切削刀刃可以制成不同的形状，但是最好不要使刀刃太窄，因为它将很快被用坏。切削刀刃最好用高速钢或钴合金高速钢。对每一个切削插入物在转动部件的外部表面上，有一个相对应的凹槽，这凹槽中可安装支持装置。凹槽的方向通常平行于转动部件的转动轴。每个凹槽的深度最好是插入物截面厚度的大约一半。这样的大小使切削刀刃被正好置于转动部件肩部的外侧，此处一般确定平板表面干扰的最外面区域。此凹槽并非本发明所绝对要求的，但是有凹槽较好，因为它们也有助于限定切削插入物并阻止它们扭曲或者在转动时移动。
卡圈46是一个连续环的形状，有许多带螺纹的径向的孔50，孔的位置相对应于切削插入及凹槽的位置。卡圈以钢制的较好。切削插入物插入它们相对应的凹槽中，该卡圈绕转动部件及插入物滑动。优选卡圈46在其内表面的插入物的位置上有弓形的切口52，以使插入物能部分地伸出到转动部件的外径之外。这是有利的，因为它使切削刀刃的位置正好处于转动部件下表面的外径的外侧。在卡圈46到位后，固定螺钉48(其大小配合径向的孔50)穿过径向的孔而向他们各自的切削插入物旋紧。由此，由于固定螺钉48的夹力而将切削插入物42限定在凹槽44中。卡圈附件可以包括单独的一个凹槽54及固定螺钉56以使卡圈46紧固在转动部件38上。
使用切削刀具的第一个实施例的操作准备中，切削插入物42置于转动部件的凹槽44中，卡圈46在转动部件38和切削插入物42上滑动，将固定螺钉48固定。在操作时，带着切削刀刃的FSW工具转动，同时把水加在切削刀刃的区域，水使切削刀刃32保持冷，以防止热搅动金属积聚在该刀刃上。带着切削刀刃的FSW工具30的线性位移使切削刀刃对它所限定的周围区域进行加工。
图11-13显示根据本发明形成的切削刀具的第二个实施例。第二个实施例的切削刀具支持装置包括：一个切削插入物柄60，其具有一个下端切削刀刃；一个插入物柄的孔62，此孔横向伸展穿过转动部件38，其方向与转动部件的转动轴64成一个角度。在转动部件38上有带螺纹的径向的孔66；配合插入径向孔66中的螺钉68，其紧固切削插入物柄60。
切削插入物柄60有矩形的截面和一个低端，在此装上一个带角的切削插入物70，其可卸下地安装。优选切削插入物70有数个伸出的角72，可以作成方形或三角形的片状物。这些角起切削刀刃的作用，其位置靠近转动部件38的肩10，其深度大约为在肩10下0.002至0.010英寸。带角切削插入物70应安装在切削插入物柄的前沿侧，也就是相对于探头转动方向的最前面。带角切削插入物优选用高速钢或钴合金高速钢制造。把切削插入物向其柄上安装可以用传统的方法完成，例如，用一个螺钉穿过切削插入物，用一个插入制动夹与切削插入物柄栓接，等。
插入物柄孔62延伸斜穿过转动部件。切削插入物柄60插入孔62中，用螺钉68固定，该螺钉与转动部件的径向孔66配合。由此，切削插入物柄被用螺钉的横向力限定在切削插入物孔中。切削插入物柄被置于此孔中，使切削刀刃稍稍凸出于肩外圆周，其深度接近肩的深度。优选切削刀刃被置于约在肩10的下面0.002至0.010英寸，相对于探头径向向外大约0.050至0.100英寸。
在使用根据第二个实施例的切削刀具操作时，带着切削刀刃的FSW工具30转动，同时沿接头前进，同时水被应用于切削刀刃在材料上的区域。水保持刀刃的冷却以防止热搅动金属积聚在刀刃面上。带着切削刀刃的FSW工具线性移动使切削刀刃对于其周边限定的区域进行加工。若切削刀刃钝了，角切削插入物可以变换方向使下一个角作为新的切削刀刃使用。
图14-16显示了根据本发明形成的切削刀具的第三个实施例。第三个实施例与第二个实施例相似，只是不用切削插入物柄，第三个实施例有一个或多个制成整体的小翼80，从转动部件靠近肩部的周边径向伸出来。这些小翼相对于转动部件的定向好像辐射的翅。图15及16显示了2个小翼。小翼可以被用传统的方法安装在转动部件38上，例如，焊接，模压，在转动部件上直接加工出等等。每个小翼焊接着一个带角的切削插入物70，其上有一个或多个角72作为切削刀刃。带角插入物70的操作基本上与上述第二个实施例相同，在此不重复。
本发明的优选实施例已如上述，应当认识到可对其作各种不同的变化而不离开本发明的精神及范围。变化的例子包括使用第二及第三实施例中的优选刀具实例切削插入物柄及带角切削插入物以代替第一优选实施例中的长的切削插入物。各种不同的槽口设计可以被用来帮助使用者装置任何一种支持物、卡圈或切削刀刃。有各种不同的方法以装配切削刀刃到转动部件上去，以代替前面详述的三种优选实施例。

Claims (24)

1.在具有装配在一个转动部件上的非自耗性的转动探头的摩擦搅动焊接工具中，其中的改进包括：
(a)一个或多个切削刀刃；及
(b)一个或多个支持装置，以将切削刀刃安装到所述转动部件上；
所述转动部件和所述非自耗性探头的转动使所述一个或多个切削刀刃同样转动，从而使所述一个或多个切削刀刃对摩擦搅动焊缝的外表面进行机加工。
2.如权利要求1的改进，其特征在于，用以安装切削刀刃的所述一个或多个支持装置使所述切削刀刃靠近所述转动部件的外周，其深度约为低于转动部件的平面0.002至0.010英寸。
3.如权利要求1的改进，其特征在于，用以安装切削刀刃的所述一个或多个支持装置包括：
(a)一个或多个切削插入物，每个切削插入物的下端有一个切削刀刃；以及
(b)将所述切削插入物可拆卸地安装到所述转动部件的外周上去的装置。
4.如权利要求3的改进，其特征在于，所述可拆卸地安装切削插入物的装置包括：
(a)在所述转动部件上形成的一个或多个凹槽，每个所述切削插入物可以配合安装到一个凹槽中去。
(b)安装到所述转动部件的外周上的一个卡圈，所述卡圈用以将每个所述切削插入物紧固到转动部件上；以及
(c)将所述切削插入物紧固在所述凹槽中的一个所希望的位置的装置。
5.如权利要求4的改进，其特征在于，在所述卡圈的内圈，在每个切削插入物的位置有切口，以允许使用不同尺寸的切削插入物。
6.如权利要求4的改进，其特征在于，所述紧固切削插入物的装置包括固定螺钉穿过卡圈上径向螺纹孔，固定螺钉用作将切削插入物压进凹槽。
7.如权利要求3的改进，其特征在于，所述切削刀刃的位置相对于转动部件的平面的深度约为0.002至0.010英寸，相对于转动部件侧面的向外距离约为0.050至0.100英寸。
8.如权利要求1的改进，其特征在于，所述用以安装切削刀刃的一个或多个支持装置包括：
(a)一个或多个带角切削插入物，每个所述切削插入物有一个或多个切削刀刃；及
(b)为在靠近所述转动部件的外周安装所述一个或多个带角切削插入物的装置。
9.如权利要求8的改进，其特征在于，所述一个或多个带角切削插入物指一个带角切削插入物及为安装此带角切削插入物的装置，包括：
(a)一个切削插入物柄，其有一个下端；
(b)转动部件上形成的一个插入物柄孔，所述切削插入物柄被配合安装在插入物柄孔中；
(c)将所述切削插入物柄紧固在所述切削插入物柄孔中一个所希望的位置上的装置；
(d)将所述带角切削插入物安装到所述切削插入物柄下端的装置。
10.如权利要求9的改进，其特征在于，所述带角切削插入物有四个角可以用作切削刀刃。
11.如权利要求9的改进，其特征在于，所述带角切削插入物被用一个螺钉可卸地安装到所述切削插入物柄上。
12.如权利要求9的改进，其特征在于，所述安装装置包括一个固定螺钉，拧入转动部件上一个径向的孔，用于把所述切削插入物柄压紧以在使用时把切削插入物柄紧固在一个特定的位置。
13.如权利要求9的改进，其特征在于，所述切削刀刃的位置相对于转动部件的平面的深度约为0.002至0.010英寸，相对于转动部件侧面向外的距离约为0.050至0.100英寸。
14.如权利要求8的改进，其特征在于，所述安装一个或多个带角切削插入物的装置包括：
(a)一个或多个小翼，其从所述转动部件的下端径向伸出；及
(b)固定每个带角切削插入物与小翼的装置。
15.如权利要求14的改进，其特征在于，所述带角切削插入物有一个或多个角，用作一个或多个切削刀刃。
16.如权利要求14的改进，其特征在于，所述带角切削插入物用一个中心螺钉可卸地与相应的小翼安装在一起。
17.如权利要求14的改进，其特征在于，所述切削刀刃的位置相对于所述转动部件的平面的深度约为0.002至0.010英寸，相对于所述转动部件侧面的向外的距离约为0.050至0.100英寸。
18.如权利要求14的改进，其特征在于，所述一个或多个小翼与所述转动部件成为整体。
19.如权利要求14的改进，其特征在于，所述切削刀刃安装到相应的小翼的前沿边的表面。
20.在一个具有一个带有非自耗性探头的转动部件的摩擦搅动焊接工艺中，其改进包括：
(a)安装一个或多个切削刀刃到转动部件上；
(b)在焊接过程中供给水，水直接加到切削刀刃上；
(c)接着，一个或多个切削刀刃的转动对摩擦搅动焊缝的外表面进行加工。
21.如权利要求20的工艺改进，其特征在于，水的温度约为1 0至30℃。
22.如权利要求20的工艺改进，其特征在于，水的供给量约为每分钟0.01至0.10加仑，以一种气-水雾混和物的形式供给。
23.如权利要求20的工艺改进，其特征在于，所述转动部件和探头的转动，相对于探头的线性移动方向，有一个稍稍向后的角度。
24.如权利要求20的工艺改进，其特征在于，所述切削刀刃可卸下地安装在所述转动部件的外表面上。
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EP0810055A1 (en) 1997-12-03
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CA2204571A1 (en) 1997-11-30
DE69700975D1 (de) 2000-01-27
CA2204571C (en) 2005-08-23
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US5794835A (en) 1998-08-18

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