CN1644293A - 复合加工装置和摩擦搅拌接合方法 - Google Patents

复合加工装置和摩擦搅拌接合方法 Download PDF

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CN1644293A
CN1644293A CNA2005100517080A CN200510051708A CN1644293A CN 1644293 A CN1644293 A CN 1644293A CN A2005100517080 A CNA2005100517080 A CN A2005100517080A CN 200510051708 A CN200510051708 A CN 200510051708A CN 1644293 A CN1644293 A CN 1644293A
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friction stir
tool
machining
instrument
machining object
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CN1321773C (zh
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吉永文雄
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Hitachi Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
    • B23Q39/00—Metal-working machines incorporating a plurality of sub-assemblies, each capable of performing a metal-working operation
    • B23Q39/02—Metal-working machines incorporating a plurality of sub-assemblies, each capable of performing a metal-working operation the sub-assemblies being capable of being brought to act at a single operating station
    • B23Q39/021—Metal-working machines incorporating a plurality of sub-assemblies, each capable of performing a metal-working operation the sub-assemblies being capable of being brought to act at a single operating station with a plurality of toolheads per workholder, whereby the toolhead is a main spindle, a multispindle, a revolver or the like
    • B23Q39/022—Metal-working machines incorporating a plurality of sub-assemblies, each capable of performing a metal-working operation the sub-assemblies being capable of being brought to act at a single operating station with a plurality of toolheads per workholder, whereby the toolhead is a main spindle, a multispindle, a revolver or the like with same working direction of toolheads on same workholder
    • B23Q39/024—Metal-working machines incorporating a plurality of sub-assemblies, each capable of performing a metal-working operation the sub-assemblies being capable of being brought to act at a single operating station with a plurality of toolheads per workholder, whereby the toolhead is a main spindle, a multispindle, a revolver or the like with same working direction of toolheads on same workholder consecutive working of toolheads
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
    • B23Q41/00—Combinations or associations of metal-working machines not directed to a particular result according to classes B21, B23, or B24
    • 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
    • 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
    • B23K20/123—Controlling or monitoring the welding process
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B23Q1/00—Members which are comprised in the general build-up of a form of machine, particularly relatively large fixed members
    • B23Q1/01—Frames, beds, pillars or like members; Arrangement of ways
    • B23Q1/012—Portals
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
    • B23Q1/00—Members which are comprised in the general build-up of a form of machine, particularly relatively large fixed members
    • B23Q1/25—Movable or adjustable work or tool supports
    • B23Q1/44—Movable or adjustable work or tool supports using particular mechanisms
    • B23Q1/48—Movable or adjustable work or tool supports using particular mechanisms with sliding pairs and rotating pairs
    • B23Q1/4852—Movable or adjustable work or tool supports using particular mechanisms with sliding pairs and rotating pairs a single sliding pair followed perpendicularly by a single rotating pair
    • B23Q1/4857—Movable or adjustable work or tool supports using particular mechanisms with sliding pairs and rotating pairs a single sliding pair followed perpendicularly by a single rotating pair followed perpendicularly by a single rotating pair
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
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    • B23Q1/00—Members which are comprised in the general build-up of a form of machine, particularly relatively large fixed members
    • B23Q1/25—Movable or adjustable work or tool supports
    • B23Q1/44—Movable or adjustable work or tool supports using particular mechanisms
    • B23Q1/50—Movable or adjustable work or tool supports using particular mechanisms with rotating pairs only, the rotating pairs being the first two elements of the mechanism
    • B23Q1/54—Movable or adjustable work or tool supports using particular mechanisms with rotating pairs only, the rotating pairs being the first two elements of the mechanism two rotating pairs only
    • B23Q1/5406—Movable or adjustable work or tool supports using particular mechanisms with rotating pairs only, the rotating pairs being the first two elements of the mechanism two rotating pairs only a single rotating pair followed perpendicularly by a single rotating pair
    • B23Q1/5425—Movable or adjustable work or tool supports using particular mechanisms with rotating pairs only, the rotating pairs being the first two elements of the mechanism two rotating pairs only a single rotating pair followed perpendicularly by a single rotating pair followed perpendicularly by a single sliding pair
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
    • B23Q1/00—Members which are comprised in the general build-up of a form of machine, particularly relatively large fixed members
    • B23Q1/25—Movable or adjustable work or tool supports
    • B23Q1/44—Movable or adjustable work or tool supports using particular mechanisms
    • B23Q1/50—Movable or adjustable work or tool supports using particular mechanisms with rotating pairs only, the rotating pairs being the first two elements of the mechanism
    • B23Q1/54—Movable or adjustable work or tool supports using particular mechanisms with rotating pairs only, the rotating pairs being the first two elements of the mechanism two rotating pairs only
    • B23Q1/5406—Movable or adjustable work or tool supports using particular mechanisms with rotating pairs only, the rotating pairs being the first two elements of the mechanism two rotating pairs only a single rotating pair followed perpendicularly by a single rotating pair
    • B23Q1/5431—Movable or adjustable work or tool supports using particular mechanisms with rotating pairs only, the rotating pairs being the first two elements of the mechanism two rotating pairs only a single rotating pair followed perpendicularly by a single rotating pair followed parallelly by a single sliding pair
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
    • B23Q1/00—Members which are comprised in the general build-up of a form of machine, particularly relatively large fixed members
    • B23Q1/25—Movable or adjustable work or tool supports
    • B23Q1/44—Movable or adjustable work or tool supports using particular mechanisms
    • B23Q1/56—Movable or adjustable work or tool supports using particular mechanisms with sliding pairs only, the sliding pairs being the first two elements of the mechanism
    • B23Q1/60—Movable or adjustable work or tool supports using particular mechanisms with sliding pairs only, the sliding pairs being the first two elements of the mechanism two sliding pairs only, the sliding pairs being the first two elements of the mechanism
    • B23Q1/62—Movable or adjustable work or tool supports using particular mechanisms with sliding pairs only, the sliding pairs being the first two elements of the mechanism two sliding pairs only, the sliding pairs being the first two elements of the mechanism with perpendicular axes, e.g. cross-slides
    • B23Q1/621—Movable or adjustable work or tool supports using particular mechanisms with sliding pairs only, the sliding pairs being the first two elements of the mechanism two sliding pairs only, the sliding pairs being the first two elements of the mechanism with perpendicular axes, e.g. cross-slides a single sliding pair followed perpendicularly by a single sliding pair
    • B23Q1/623—Movable or adjustable work or tool supports using particular mechanisms with sliding pairs only, the sliding pairs being the first two elements of the mechanism two sliding pairs only, the sliding pairs being the first two elements of the mechanism with perpendicular axes, e.g. cross-slides a single sliding pair followed perpendicularly by a single sliding pair followed perpendicularly by a single rotating pair
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
    • B23Q1/00—Members which are comprised in the general build-up of a form of machine, particularly relatively large fixed members
    • B23Q1/25—Movable or adjustable work or tool supports
    • B23Q1/44—Movable or adjustable work or tool supports using particular mechanisms
    • B23Q1/56—Movable or adjustable work or tool supports using particular mechanisms with sliding pairs only, the sliding pairs being the first two elements of the mechanism
    • B23Q1/60—Movable or adjustable work or tool supports using particular mechanisms with sliding pairs only, the sliding pairs being the first two elements of the mechanism two sliding pairs only, the sliding pairs being the first two elements of the mechanism
    • B23Q1/62—Movable or adjustable work or tool supports using particular mechanisms with sliding pairs only, the sliding pairs being the first two elements of the mechanism two sliding pairs only, the sliding pairs being the first two elements of the mechanism with perpendicular axes, e.g. cross-slides
    • B23Q1/621—Movable or adjustable work or tool supports using particular mechanisms with sliding pairs only, the sliding pairs being the first two elements of the mechanism two sliding pairs only, the sliding pairs being the first two elements of the mechanism with perpendicular axes, e.g. cross-slides a single sliding pair followed perpendicularly by a single sliding pair
    • B23Q1/625—Movable or adjustable work or tool supports using particular mechanisms with sliding pairs only, the sliding pairs being the first two elements of the mechanism two sliding pairs only, the sliding pairs being the first two elements of the mechanism with perpendicular axes, e.g. cross-slides a single sliding pair followed perpendicularly by a single sliding pair followed parallelly by a single rotating pair
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
    • B23Q37/00—Metal-working machines, or constructional combinations thereof, built-up from units designed so that at least some of the units can form parts of different machines or combinations; Units therefor in so far as the feature of interchangeability is important
    • B23Q37/002—Convertible machines, e.g. from horizontally working into vertically working
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
    • B23Q7/00—Arrangements for handling work specially combined with or arranged in, or specially adapted for use in connection with, machine tools, e.g. for conveying, loading, positioning, discharging, sorting
    • B23Q7/02—Arrangements for handling work specially combined with or arranged in, or specially adapted for use in connection with, machine tools, e.g. for conveying, loading, positioning, discharging, sorting by means of drums or rotating tables or discs
    • 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
    • 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T483/00—Tool changing
    • Y10T483/17—Tool changing including machine tool or component
    • 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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    • Y10T483/17—Tool changing including machine tool or component
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    • Y10T483/1748—Tool changer between spindle and matrix
    • 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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    • Y10T483/1733—Rotary spindle machine tool [e.g., milling machine, boring, machine, grinding machine, etc.]
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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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    • 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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    • Y10T483/1793—Spindle comprises tool changer
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Abstract

提供一种可以在一台机械上进行切削和接合的复合加工装置。可以同时控制的5个轴的运动坐标系由3个直线移动轴和绕上述任一轴旋转的2个旋转轴构成，在上述5轴中的1轴上附加工具旋转功能构成的加工装置中，设置切削加工工具51和摩擦搅拌接合工具52，这时监视摩擦搅拌接合的工具52旋转轴的转矩电流，预先设定工具52的大径部接触加工物时的电流值，通过以使该电流值不下降地控制工具52的插入量可以进行良好的接合，可以用一台机械进行切削和接合，可以削减设备成本、占用场地、建筑面积、加工准备时间和加工成本。

Description

复合加工装置和摩擦搅拌接合方法
本申请为株式会社日立制作所于2001年2月15日提交的、申请号为“01104536.1”、发明名称为“复合加工装置和摩擦搅拌接合方法”的发明专利申请的分案申请。
技术领域
本发明涉及进行金属材料的切削和摩擦搅拌接合的装置及其方法。例如，适用于机械零件和构造物零件等的加工组装。
背景技术
机械零件和构造物零件等的加工组装用各自的加工装置进行加工，切削加工用切削工作机械，接合组装用各种焊接接合装置。
由切削工作机械进行的复合加工，几乎都是在复合车床上车削和旋转工具加工及在加工中心上的旋转工具加工和车刀加工那样的切削加工中的复合加工，作为切削加工以外的组合有旋转工具加工和激光淬火的组合。
作为接合方法，有摩擦搅拌接合方法(特开平11-90655号公报(USP6050474))。这是边旋转插入接合部的圆棒(叫旋转工具)边沿接合线移动，使接合部发热、软化、塑性流动、固相接合的方法。旋转工具由插入接合部的小径部(叫杆)和位于外部的大径部(叫肩)构成。小径部和大径部同轴。使大径部侧旋转。在接合部上设置凸部。
另外，如特表平9-508073号公报(EP0752926b1)所述那样，旋转工具倾斜地插入构件。倾斜方向是在旋转工具移动方向上使旋转工具的小径部位于旋转工具的大径部的前方。即，旋转工具向后方倾斜。
如上所述，现在还没有以在一台加工机械上进行切削和接合为目的而设计制造的加工机械。
因此，为了进行切削加工和接合加工需要切削工作机械和接合加工装置二种类型的加工设备。因此存在设备成本高、占用场地大、建筑面积大、用于从切削到接合的等待时间长、需要切削和接合的操作人员等缺点。
发明内容
本发明的目的在于，提供一种可以用一台机械进行切削和接合的复合加工装置。
为了达到上述目的，本发明的复合加工装置由X、Y、Z各直线移动装置、绕A、B各转轴旋转的旋转装置、可以同时控制该5个坐标系的控制装置、使工具旋转的主轴、用于保管上述主轴使用的多个工具的保管装置、用于在上述主轴和上述保管装置之间交换工具的交换装置构成，上述保管装置可以备有切削工具和摩擦搅拌接合工具，上述控制装置根据程序把上述切削工具或者上述摩擦搅拌接合工具从上述保管装置经上述交换装置安装到上述主轴上，由安装在上述主轴上的工具进行加工。
附图说明
图1是本发明的一个实施例的加工装置的立体图。
图2是由复合加工装置进行切削加工时的立体图
图3是由复合加工装置进行摩擦搅拌接合时的立体图。
图4是摩擦搅拌接合时的纵向剖视图。
图5是表示摩擦搅拌接合工具的插入和转矩电流的关系的图。
图6是表示本发明的一个实施例的加工过程的流程图。
图7是本发明的另一个实施例的加工装置的立体图。
图8是本发明的另一个实施例的加工装置的立体图。
图9是本发明的另一个实施例的加工装置的立体图。
具体实施方式
下面，根据图1至图6说明作为本发明的一个实施例的加工中心型的复合加工装置。该装置由沿X轴方向移动的工作台(移动台)11、设置在其上方的横梁21上的沿Y轴方向移动的移动台31、设置在移动台31上的沿Z轴方向移动的移动台32、设置在移动台32上的沿C轴方向旋转的旋转台33、设置在旋转台33上的沿B轴方向旋转的旋转台34和设置在旋转台34上的旋转安装工具的主轴35构成。旋转台34具有使主轴35旋转的电动机。
主轴35可以有选择地安装切削工具51和摩擦搅拌接合工具52。主轴35可以以适合于工具51、52的转速旋转。工具保管装置40图未示，但可以分别保管多个切削工具51、摩擦搅拌接合工具52。在主轴35和工具保管装置40之间，通过工具交换装置(图未示)，可以交换工具并把所需要的工具51、52安装在主轴35上。不仅是工具，包含工具的轴承等的所谓加工头也可以进行交换，X、Y、Z方向的各移动台11、31、32的驱动机构、旋转台33、34的驱动机构、工具交换装置都是公知的机构和装置。
由于同时对这样的3个直线移动轴和2个旋转轴共5个轴进行控制，所以得到了特别适合于立体形状的切削加工和摩擦搅拌接合的复合加工装置。
加工物101安装在工作台11上，加工物101是曲面状的板零件。
在图2中，对切削加工进行说明。在5轴切削加工中，可以使主轴35(工具51、52的旋转轴)直角地作用在加工物101的曲面上并移动。因此与现有的2轴或者3轴那样不能倾斜工具姿势的加工相比，工具突出的长度变短，可从在工具系刚性大的状态下进行加工。因此，很少产生高频振动和一般振动，可以进行切削速度高的高效率的切削。
另外，在5轴切削加工中，由于可以自由地设定主轴35的姿势，所以可以使切削工具51的轴A比加工物的接合部的法线R只倾斜后倾角θ，即，相对于曲面后倾地进行加工。在平面工具中，可以使切削刃部分地起作用来进行加工。因此与全面接触加工相比，切削阻力变小，很少发生高频振动和一般振动，可以进行切削速度高的高效率的加工。
在图3和图4中，对摩擦搅拌接合进行说明。对加工物101、102的对接部进行接合。在加工物101、102的端部的对接部上分别有向上方突出的凸部101b、102b。该加工物101、102是由上述切削制作的，在图3中，没有表示凸部101b、102b。在图4中表示了凸部101b、102b。加工101、102是有曲面的板。摩擦搅拌接合工具52由大径部52b和其前端部的小径部52c构成。小径部52c插入需要接合的部分。大径部52b的最下端处于加工物的不是凸部101b、102b的部分的上面的延长线和凸部101b、102b的顶部之间。2个凸部101b、102b的宽度比大径部52b的直径大。工具52的轴A在工具52的移动方向上进行倾斜以使大径部52b的轴心位于小径部52c的轴心的后侧。由于工具52边旋转边沿对接部(接合线)移动，所以可以进行摩擦搅拌接合。
加工物101、102通过支持台(图未示)承载在工作台11上。加工物101、102通过支持台牢固地固定在工作台11上。特别是在需要接合的对接部的下方有支持台，这是用于支持摩擦搅拌接合时的大的荷重的。
2个加工物101、102的对接部上即使有间隙，由于大径部52b压下的凸部101b、102b的金属成为填埋上述间隙的原材料，所以可以进行良好的接合。
在没有凸部101b、102b时，由于把大径部52b若干插入加工物101、102的面内进行摩擦搅拌接合，所以，在接合部会有凹部。
为了沿曲面同时相对移动方向倾斜地移动，另外为了移动到所希望的位置，同时控制运动坐标系5轴是有效的。
由于在加工物101、102上存在着制造误差，只按照NC(数值控制)程序表移动工具，很难确保工具的插入位置。
图5是把摩擦搅拌接合工具52插入加工物时旋转工具52的电动机的转矩电流和工具52的插入深度的关系的模式图。插入深度是从加工物101、102的表面到小径部52c的前端的距离。随着工具52的插入深度的增加，转矩电流缓慢地增加到IS。当工具52的大径部52b的端部插入加工物内时转矩电流I急剧地增加，达到Iα。之后的增加由于大径部52b的直径是一定的而是缓慢的。工具52在如上所述地倾斜地插入时，从小径部52c的前端与加工物开始接触到大径部52b的端部接触开始的距离S之间，随着插入深度的增加转矩电流平缓地增加而到达Is。工具52的大径部52b的端部插入加工物中时，转矩电流在直到大径部52b的端部全面接触的距离α之间急剧地增加，到达Iα。
因此，要控制工具52的插入深度，以使转矩电流值成为Iα以上的规定的电流值。因此，即使加工物是曲面，有制造误差，也可以维持规定的插入深度，可以进行良好的摩擦搅拌接合。
工具52的转矩电流通过检测主轴35的电动机的电流值来求出。由于使用交流伺服电动机或者直流伺服电动机转动主轴35，所以可以正确地检测转矩电流。把该转矩电流作为判断值，通过使上述移动台32上下移动，通常可以保证最适宜的插入深度。另外，通过监视转矩电流也可以检测工具的损伤。
另外，根据转矩电流值I，特别是Iα以上的规定值的检测，可以检测当时的移动台32的下降位置。由此可以检测加工物101、102的位置。对预先给定的加工物101、102的坐标值与使工具52移动的NC(数值控制)数据之差进行修正。据此可以得到工具52向加工物101、102的正确插入深度。
加工物101、102的位置根据下面的方法也可以检测。构成经过11、21、31、32、33、34、35、工具52、加工物101、102的通电回路。在其途中配置高频电源和它的检测器。摩擦搅拌接合开始时，使移动台32下降，使工具52的小径部52c的前端与加工物101、102接触。由此构成高频电流的回路，用检测器检测它。求出检测时的工具52的位置。而且对预先给定的加工物101、102的坐标值和使工具52移动的NC(数值控制)数据之差进行修正。据此可以得到正确的插入深度。而且，之后可以根据转矩电流I的检测将工具52的插入深度管理为规定值。
下面，根据图6对加工物的制作过程进行说明。把加工物101、102承载在工作台11上，由工具51主要对其上面进行切削。这时，残留凸部101b地进行切削。接下来，搬下加工物101，放置加工物102。同样地切削加工物102。加工物101、102是铝合金制的板。该板有曲面。切削是干切削，干清洗。在把加工物102固定在工作台11上时，考虑到后面的摩擦搅拌接合，通过支持台固定加工物102(工序S10)。
接下来，通过支持台(图未示)把加工物101载置在工作台11的上面，与加工物102对接，固定在工作台11上。另外，由工具交换装置在工具保管装置40和主轴35之间交换工具，把摩擦搅拌接合工具52安装在主轴35上(工序S20)。
接下来，使主轴35旋转，使上述对接部进行摩擦搅拌接合(工序S30)。
使工具52边旋转边下降，插入到规定位置，开始摩擦搅拌接合。加工物101、102的高度位置，如上所述，可以用高频电流检测，也可以用转矩电流值I检测。通过该高度位置的检测进行加工物101、102等的坐标的修正。
接下来，根据预先设定的NC数据，使工具52沿对接部(接合线)移动。在使工具52沿接合线移动时，用转矩电流值I控制工具52的插入深度。
使工具52沿接合线移动的控制也可以根据预先给定的坐标(NC数据)来进行，也可以根据检测接合线的位置的检测器的数据来进行。检测器是光学传感器，设置在旋转台34上。检测器检测对接部的间隙和凸部101b、102b的端部的边缘，求出对接部的位置。引导工具52到求出的位置。另外，可以用求出的数据修正上述坐标并进行引导。另外，用光学传感器求出凸部101b、102b的高度，可以控制插入的深度。
接下来，在摩擦搅拌接合终了之后，把主轴35的工具换成切削工具(工序S40)。
接下来，进行切削加工(S50)。作为切削是切削对接部的凸部101b、102b。通过切削使对接部与其他部分的曲面实质上成为同一曲面。这对于把加工物101、102的上面作为制品的外面的情况是有效的。当然也可以把凸部和上述其它部分的曲面都进行切削。
另外，再把成为一体的加工物101、102的外周部等切削成规定的形状。另外，在上述其他部分曲面上用切削工具51加工出孔、螺纹、凹部等，由于在对接加工物101、102时有间隙，所以在摩擦搅拌接合后的地方可以高精度地加工。
另外，由于摩擦搅拌接合终了，当工具52从加工物101、102中拔出时，在其部分上产生孔，把该孔边切削成大径的孔边或在该孔内加工螺纹。为了加工螺纹，拔出工具52的位置，也可以不是摩擦搅拌接合的接合位置。
切削后进行摩擦搅拌接合时，用于切削的油和切削后清扫用油对摩擦搅拌接合有坏的影响，另外，切屑也会使2个构件的组合精度变坏。然而，如果在摩擦搅拌接合之后进行切削，这些问题就可以被去除。在摩擦搅拌接合之前进行2个构件的切削，该切削油的去除完全可以用其他的机械进行。
再有，在工序S10中，如果加工物101、102的对接部能够进行适合摩擦搅拌接合那样的对接，在使加工物101、102对接并载置在工作台11上的状态下，可以进行上述切削。这时在对接部的下方配置支持台。
另外，可以用第1旋转工具摩擦搅拌接合1组加工物，接下来，在主轴和工具保管装置之间交换旋转工具，然后用第2旋转工具摩擦搅拌接合上述1组加工物的第2接合部。
对图7的实施例进行说明。这是相对一个工作台11设置2个加工装置30、30B的设备，2个加工装置30、30B设置在1个横梁21上。2个加工装置30、30B的构成和功能是像上述的装置那样，两者实质上是相同的。在一个加工装置30的主轴上设置摩擦搅拌接合工具52。横梁21的两端从工作台11的端部突出，一个加工装置进行加工作业时，另一个加工装置可以退避到突出的横梁上。
如果这样，就不需要交换工具。另外，由于在摩擦搅拌接合时需要大的插入力，所以，主轴的轴承等必须是高强度的。在摩擦搅拌接合时与一般的切削相比，主轴的转速可以低些，因此，如果分别制作切削用加工装置30、摩擦搅拌接合加工装置30B，可以比较廉价地构成摩擦搅拌接合装置。
对图8的实施例进行说明。该实施例的设备由沿水平(X轴)方向移动的柱61、设置在柱61上垂直(Y轴)方向移动的移动台63、设置在移动台63上的使安装的工具旋转的主轴65、沿主轴65的旋转轴的水平(Z轴)方向移动的移动台71、设置在移动台71的绕B轴旋转的旋转台73和设置在旋转台73上的绕A轴旋转的工作台74构成。在主轴65和工具保管装置68之间，通过工具交换装置(图未示)可以交换切削工具51和摩擦搅拌接合工具52，可以同时控制直线移动轴3轴，绕轴旋转的旋转轴2轴共5轴。
主轴65在水平上不能变更角度，使工作台74相对主轴倾斜，设定上述后倾角θ。
对图9的实施例进行说明，加工物111安装在旋转台81上，加工物112的端部插入加工物111的前端，两者被核对。加工物112的前端支持在尾座83上。对加工物111和112的对接部进行摩擦搅拌接合，在两者的端部上有凸部111b、112b。有沿旋转台81的轴心移动并沿上下方向移动的移动台91。在移动台91上有以45度的角度旋转的旋转台92。在旋转台92上有旋转工具52的主轴95。在旋转台92上有设置切削工具53的刀杆96。不需要刀杆96旋转。切削工具是车刀。
在圆筒状的加工物111的端部上插入加工物112的端部，对接两者。对接部也可以用电弧焊进行点焊。将其安装在旋转台81上，用尾座支持加工物112。使旋转台81和主轴95旋转，摩擦搅拌接合对接部。接下来，使旋转台92旋转，使车刀53与摩擦搅拌接合部相对。然后，旋转旋转台81，切削接合部的凸部。摩擦搅拌接合的方向可以是除了筒的圆周以外的任意方向。用夹具96进行的切削为周围方向。
对与设置在工作台和旋转台上的加工物进行接合的加工物的设置可以用机器人装置进行。
本发明的技术范围不限于权利要求书中各项权利要求所述的内容或者用于解决课题的各项技术方案所述的内容。也涉及本行业人员容易置换的范围。例如，复合加工装置的外观和体积、工具的大小等不同都包含在本发明的范围内。
根据本发明，由于一台就可以进行切削加工和接合加工，所以可以削减设备费用、安放场地、建筑面积、加工准备时间和加工成本。

Claims (1)

1.一种摩擦搅拌接合方法，其特征在于，检测摩擦搅拌接合中的摩擦搅拌接合工具用旋转轴的转矩电流值，根据该检测值控制上述摩擦搅拌接合工具向加工物的插入量。
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CN1644294A (zh) 2005-07-27
CN1321772C (zh) 2007-06-20
AU782965B2 (en) 2005-09-15
US20020050508A1 (en) 2002-05-02
CN1644308A (zh) 2005-07-27
KR20020033014A (ko) 2002-05-04
KR100500514B1 (ko) 2005-07-14
US20020193217A1 (en) 2002-12-19
CN100389930C (zh) 2008-05-28
AU2310101A (en) 2002-05-02
US6645132B2 (en) 2003-11-11
US20020190103A1 (en) 2002-12-19

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