GB2250837A - Controlled amplitude linear friction bonding. - Google Patents

Controlled amplitude linear friction bonding. Download PDF

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Publication number
GB2250837A
GB2250837A GB9026920A GB9026920A GB2250837A GB 2250837 A GB2250837 A GB 2250837A GB 9026920 A GB9026920 A GB 9026920A GB 9026920 A GB9026920 A GB 9026920A GB 2250837 A GB2250837 A GB 2250837A
Authority
GB
United Kingdom
Prior art keywords
amplitude
oscillation
linear friction
friction bonding
articles
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB9026920A
Other versions
GB9026920D0 (en
Inventor
John Walker Daines
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Rolls Royce PLC
Original Assignee
Rolls Royce PLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Rolls Royce PLC filed Critical Rolls Royce PLC
Priority to GB9026920A priority Critical patent/GB2250837A/en
Publication of GB9026920D0 publication Critical patent/GB9026920D0/en
Priority to PCT/GB1991/002202 priority patent/WO1992010328A1/en
Priority to EP19920900363 priority patent/EP0561865A1/en
Publication of GB2250837A publication Critical patent/GB2250837A/en
Withdrawn legal-status Critical Current

Links

Classifications

    • 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
    • B29C65/0609—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 characterised by the movement of the parts to be joined
    • B29C65/0618—Linear
    • 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
    • B23K20/1205—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 translation movement
    • 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
    • B23K20/121—Control circuits therefor
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/95—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94
    • B29C66/951—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 by measuring or controlling the vibration frequency and/or the vibration amplitude of vibrating joining tools, e.g. of ultrasonic welding tools
    • B29C66/9515—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 by measuring or controlling the vibration frequency and/or the vibration amplitude of vibrating joining tools, e.g. of ultrasonic welding tools by measuring their vibration amplitude
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/95—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94
    • B29C66/951—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 by measuring or controlling the vibration frequency and/or the vibration amplitude of vibrating joining tools, e.g. of ultrasonic welding tools
    • B29C66/9516—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 by measuring or controlling the vibration frequency and/or the vibration amplitude of vibrating joining tools, e.g. of ultrasonic welding tools by controlling their vibration amplitude
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/92—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools
    • B29C66/924—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force, the mechanical power or the displacement of the joining tools
    • B29C66/9241—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force, the mechanical power or the displacement of the joining tools by controlling or regulating the pressure, the force or the mechanical power
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/93—Measuring or controlling the joining process by measuring or controlling the speed
    • B29C66/934—Measuring or controlling the joining process by measuring or controlling the speed by controlling or regulating the speed
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/94—Measuring or controlling the joining process by measuring or controlling the time
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/95—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94
    • B29C66/951—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 by measuring or controlling the vibration frequency and/or the vibration amplitude of vibrating joining tools, e.g. of ultrasonic welding tools
    • B29C66/9511—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 by measuring or controlling the vibration frequency and/or the vibration amplitude of vibrating joining tools, e.g. of ultrasonic welding tools by measuring their vibration frequency
    • 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
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/95—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94
    • B29C66/951—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 by measuring or controlling the vibration frequency and/or the vibration amplitude of vibrating joining tools, e.g. of ultrasonic welding tools
    • B29C66/9512—Measuring or controlling the joining process by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94 by measuring or controlling the vibration frequency and/or the vibration amplitude of vibrating joining tools, e.g. of ultrasonic welding tools by controlling their vibration frequency

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)

Abstract

In a linear friction bonding process the amplitude of oscillation between the parts being bonded is sensed in a plane adjacent the interface between the parts, is compared with an ideal amplitude, and is adjusted by means of a feedback loop so as to achieve the ideal amplitude.

Description

INPROVBMESTS IN OR RELATING TO LINEAR FRICTION BONDING This invention concerns improvements in or relating to linear friction bonding.
Linear friction bonding is a technique for welding together two articles at an interface between them, the articles usually, but not necessarily, being metal and the interface planar; and comprises oscillating one article against the other in a linear direction by means of an operating mechanism which simultaneously imposes a load on the articles in a direction normal to the interface (i.e. presses them together), until sufficient heat is generated, in the first instance to soften the interface, and secondly to assist the pressure applied to achieve a solid phase weld between the articles.The articles may, for example, be a turbine or compressor blade and a rotor disk for an aircraft gas turbine engine. "Metal", in the context of this invention, includes not only elemental metals but alloys of metals, and of a metal or metals with a non-metallic substance such as a ceramic.
Among the advantages of linear friction bonding are that it does not need relatively expensive welding materials or atmospheres, or specialist welding skills, and is quick. However, successful linear friction bonding does depend on critical parameters such as: the imposed loading, the amplitude and frequency of the oscillation, and the total period of time during which the articles are subjected to the oscillation.
Hitherto, it has been the practice to preset the amplitude of the oscillation to a predetermined value while the operating mechanism is stationary, i.e. while the articles are under zero load and the oscillation frequency is zero. In practice, it is found that this raises a problem due to inherent elasticity of the operating mechanism and its related tooling, and backlash in the mechanism. Under operating conditions the effect of inertia and the in-plane force at the interface between the articles being bonded, in combination with the inherent elasticity and backlash of the operating mechanism will cause the amplitude of oscillation to be unpredictably different from that intended (i.e. the predetermined value), with a resulting loss of control of process parameters.This is particularly so when the process of linear friction bonding is applied to articles having a large interface area.
Hitherto, one approach to this problem has been to set the predetermined amplitude of oscillation under zero conditions to a higher value than that required by operating conditions, in the hope that the desired result will be obtained under operating conditions.
However, this can provide a useful result only for one particular set of operating parameters, and has the further disadvantage of taking up clearances which could otherwise be allocated to tooling, i.e. the tooling could be made more rigid.
It is an object of the present invention to overcome the above disadvantages and to provide a means whereby the amplitude of oscillation in a linear friction bonding process is maintained substantially at its preset value under operating conditions.
In general, the present invention senses the amplitude of oscillation in a linear fricton bonding process between the articles being bonded and automatically adjusts the amplitude so that a predetermined amplitude is achieved under operating conditions.
According to the present invention there is provided a method of controlling a linear friction bonding process in which two articles are oscillated in a linear direction relative to one another whilst simultaneously being pressed together, so as to be welded together by the friction of the oscillation, the method comprising monitoring the value of the amplitude of the oscillation, comparing the monitored amplitude of the oscillation with a predetermined value of the amplitude, deriving a signal from any difference therebetween, and using said derived signal to change the amplitude of the oscillation so as to at least reduce said difference.
The method may include measuring the rate of change of the monitored value of the amplitude of oscillation with respect to time and using that rate of change to modify said derived signal so as to reduce any tendency of the changed amplitude of oscillation to hunt.
Preferably, the method comprises monitoring the value of the amplitude of oscillation adjacent the interface between the articles being bonded.
The invention will now be described by way of example only with reference to the accompanying drawings, in which, Figure 1 is a schematic block diagram of a linear friction bonding machine according to the invention, and Figure 2 is a flow chart of a program for a computer, for use in operation of the machine of Figure 1.
Referring to Figure 1 there are shown two abutting metal components 10, 12 having a common planar interface 14, which are to be bonded together at the interface by linear friction bonding.
One component 10 is rigidly held in a vice (not shown), and the other component 12 is moved laterally to and fro across the interface 14 in the direction of arrows 16 by means of an oscillating mechanism arranged to induce this movement, such a mechanism being well known in the art and depicted generally by box 18. The amplitude of the oscillatory movement is controlled by an amplitude control hydraulic ram, indicated schematically by box 20.
The loading applied to component 12 in a direction normal to the plane of the interface 14, so as to press the components 10, 12 together, is provided by a hydraulic system indicated generally by box 22.
The lateral motion of component 12 relative to component 10 is sensed in a plane adjacent and parallel to the interface 14 by means of a linear variable differential transformer 24 which also measures the amplitude of the oscillation and sends a signal indicative thereof to a control module 26.
The control module 26 includes a computer and a look-up table containing ideal values of the amplitude of oscillation as a function of the applied loading and the frequency of oscillation. These ideal, or required, values of the amplitude may be obtained experimentally, or may be calculated from theoretical considerations, and inserted in the look-up table; alternatively, the values may be calculated algorithmically in real time, if a suitable algorithm is available.
The operation of the invention will now be described with reference to the flow chart of Figure 2.
The machine is set up so as to bring the metal components 10, 12 that are to be bonded, into contact.
The speed and amplitude of oscillation, and the loading, are set up as required by appropriate setting of the oscillating mechanism 18, the amplitude control hydraulic ram 20, and the hydraulic loading system. The bonding operation in the form of a feed-back loop is now started.
The bonding operation commences by first checking to see whether the operation is in fact complete. This may be ascertained by checking one or more of a number of parameters have reached a preset value. These parameters may include time, number of cycles round the feed-back loop, the number of oscillations, and the amount of upset produced between the bonded components.
If the operation is complete then the mechanism is stopped and the bonded components removed. The parameters may also include an instruction to halt the machine in the event of safety being breached, or otherwise.
If the bonding operation is to continue, the actual frequency of the oscillation and the loading are read and fed into the computer of the control module 26.
Here the ideal amplitude of oscillation required corresponding to that particular frequency and loading is calculated, either from a look-up table or algorithmically as indicated above. The actual amplitude is then measured and compared with the stored required amplitude.
If the actual amplitude is greater than the stored required amplitude, then the difference between the two is determined and a proportional signal is sent to the amplitude control ram 20 instructing it to reduce the pressure controlling the amplitude of oscillation. The amplitude of oscillation is thereby reduced and the next cycle of the loop commences.
If the actual amplitude is the same as the stored required amplitude, then no signal is sent to the amplitude control ram 20, and the next cycle of the loop commences.
If the actual amplitude is less than the stored required amplitude, then the difference between the two is determined and a proportional signal is sent to the amplitude control ram 20 instructing it to increase the pressure controlling the amplitude of oscillation. The amplitude of oscillation is thereby increased and the next cycle of the loop commences.
In an alternative embodiment, the rate of change of the amplitude of oscillation may also be measured and used to provide second-order feed-back control of the amplitude of oscillation. This is useful if it is found that the system has a tendency to "hunt".

Claims (4)

CLAIMS:
1. A method of controlling a linear friction bonding process in which two articles are oscillated in a linear direction relative to one another whilst simultaneously being pressed together, so as to be welded together by the friction of the oscillation, the method comprising monitoring the value of the amplitude of the oscillation, comparing the monitored amplitude of the oscillation with a predetermined value of the amplitude, deriving a signal from any difference therebetween, and using said derived signal to change the amplitude of the oscillation so as to at least reduce said difference.
2. A method as claimed in Claim 1 including measuring the rate of change of the monitored value of the amplitude of oscillation with respect to time and using that rate of change to modify said derived signal so as to reduce any tendency of the changed amplitude of oscillation to hunt.
3. A method as claimed in Claim 1 or 2 comprising monitoring the value of the amplitude of oscillation adjacent the interface between the articles being bonded.
4. A method of controlling a linear friction bonding process substantially as hereinbefore described with reference to the accompanying drawings.
GB9026920A 1990-12-11 1990-12-11 Controlled amplitude linear friction bonding. Withdrawn GB2250837A (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
GB9026920A GB2250837A (en) 1990-12-11 1990-12-11 Controlled amplitude linear friction bonding.
PCT/GB1991/002202 WO1992010328A1 (en) 1990-12-11 1991-12-11 Improvements in or relating to linear friction bonding
EP19920900363 EP0561865A1 (en) 1990-12-11 1991-12-11 Improvements in or relating to linear friction bonding

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB9026920A GB2250837A (en) 1990-12-11 1990-12-11 Controlled amplitude linear friction bonding.

Publications (2)

Publication Number Publication Date
GB9026920D0 GB9026920D0 (en) 1991-01-30
GB2250837A true GB2250837A (en) 1992-06-17

Family

ID=10686853

Family Applications (1)

Application Number Title Priority Date Filing Date
GB9026920A Withdrawn GB2250837A (en) 1990-12-11 1990-12-11 Controlled amplitude linear friction bonding.

Country Status (3)

Country Link
EP (1) EP0561865A1 (en)
GB (1) GB2250837A (en)
WO (1) WO1992010328A1 (en)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2257077A (en) * 1991-06-29 1993-01-06 Hydro Marine Systems Limited A control system
US7624907B2 (en) * 2007-06-15 2009-12-01 Cyril Bath Company Linear friction welding apparatus and method
WO2016207851A1 (en) * 2015-06-25 2016-12-29 Ecole Polytechnique Federale De Lausanne (Epfl) Ultrasonic driving method

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AT411883B (en) * 2002-09-30 2004-07-26 Voestalpine Schienen Gmbh METHOD FOR METALLICALLY CONNECTING BARS
CN111203630B (en) * 2020-04-20 2020-08-04 中国航空制造技术研究院 Precision control method for linear friction welding upset forging direction and application

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2008809A (en) * 1977-11-10 1979-06-06 Mclean R F A system for vibrating a body
GB2030731A (en) * 1978-09-20 1980-04-10 Nat Res Dev Vibratory Conveyors
GB2044490A (en) * 1979-03-19 1980-10-15 Automation Devices Inc Constant amplitude controller with feedback control for a vibratory feeder apparatus
EP0128759A2 (en) * 1983-06-10 1984-12-19 The Arthur G. Russell Company, Incorporated Control circuit for vibratory devices
US4844320A (en) * 1987-02-17 1989-07-04 General Electric Company Control system and method for vibration welding

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4715523A (en) * 1984-11-12 1987-12-29 Lebedev Vladimir K Electromagnetic power drive for a friction welding machine
DE4001367A1 (en) * 1990-01-18 1991-09-19 Branson Ultraschall DEVICE FOR SETTING A MACHINE PARAMETER IN FRICTION WELDING

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2008809A (en) * 1977-11-10 1979-06-06 Mclean R F A system for vibrating a body
GB2030731A (en) * 1978-09-20 1980-04-10 Nat Res Dev Vibratory Conveyors
GB2044490A (en) * 1979-03-19 1980-10-15 Automation Devices Inc Constant amplitude controller with feedback control for a vibratory feeder apparatus
EP0128759A2 (en) * 1983-06-10 1984-12-19 The Arthur G. Russell Company, Incorporated Control circuit for vibratory devices
US4844320A (en) * 1987-02-17 1989-07-04 General Electric Company Control system and method for vibration welding

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2257077A (en) * 1991-06-29 1993-01-06 Hydro Marine Systems Limited A control system
GB2257077B (en) * 1991-06-29 1994-11-16 Hydro Marine Systems Limited A control system
US7624907B2 (en) * 2007-06-15 2009-12-01 Cyril Bath Company Linear friction welding apparatus and method
US7882996B2 (en) 2007-06-15 2011-02-08 Cyril Bath Company Linear friction welding apparatus using counter load actuators
WO2016207851A1 (en) * 2015-06-25 2016-12-29 Ecole Polytechnique Federale De Lausanne (Epfl) Ultrasonic driving method

Also Published As

Publication number Publication date
GB9026920D0 (en) 1991-01-30
WO1992010328A1 (en) 1992-06-25
EP0561865A1 (en) 1993-09-29

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