JP2001129674A - Friction welding device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a device for friction welding a long and large-scaled structure such as a vehicle while stably fixing. SOLUTION: The rollers 7 for pressing workpieces 2 are arranged near a rotary tool 1, and support the workpieces 2 together with the rollers 8 arranged opposite to the rollers 7. Friction welding is performed by synchronously moving these rollers 7, 8 and rotary tool 1.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention can be applied to all structures such as automobiles, ships, aviation, elevators, pressure vessels, etc., in addition to vehicle structures made of aluminum alloy.

[0002]

2. Description of the Related Art As a friction welding method, Japanese Patent Application Laid-open No.
090, a tool made of a material substantially harder than the workpiece.
The tool is inserted into the welded part of the workpiece, and the tool is moved while rotating the tool, so that the workpiece is friction-welded by plastic flow due to frictional heat generated between the rotating tool and the workpiece. A known welding method is known.

[0003] In the conventional friction welding method, in contrast to a method in which workpieces are rotated and welding is performed by frictional heat between the workpieces, Japanese Patent Application Laid-Open No. 7-505050 discloses a method in which a welding member is fixed. The tool can be joined by moving the tool while rotating it. Therefore, there is an advantage that even a member that is substantially infinitely long in the welding direction can be continuously solid-phase bonded in the longitudinal direction. Furthermore, since solid-state welding is performed using plastic flow of metal due to frictional heat between the rotary tool and the welding member, the joining can be performed without melting the joint.
Further, since the heating temperature is low, deformation after bonding is small. Since the joint is not melted, there are many advantages, such as fewer defects.

[0004]

Problems to be Solved by the Invention, Japanese Patent Application Laid-Open No. 7-50 / 1990
Inserting a rotary tool according to 5090 into the workpiece,
When the friction welding method of welding by rotating and moving the rotary tool is applied to a long and large structure such as a vehicle structure, there are the following problems.

(1) The workpiece deforms during welding due to the load of the rotating tool. Therefore, the workpiece during welding is as described above.
It is necessary to fix the work from the front, back, or side of the work to withstand the force of the rotating tool. Particularly, the back surface of the welded portion opposite to the rotary tool receives the load of the rotary tool, so that it is necessary to arrange a strong member. However, in the case of a workpiece such as a large vehicle having a long welding length, it is difficult to fix the workpiece.

(2) The present welding method utilizes frictional heat between the rotating tool and the workpiece. Therefore, the surface of the weld is
A dent is formed by friction between the rotating tool and the workpiece surface. Because of this, the thickness of the weld substantially decreases,
The strength of the joint decreases, and there is a problem in reliability.

(3) When there is a gap in the joint at the joint, a defect is likely to occur. That is, conventional MIG or T
The allowable range of the gap is narrower than the fusion welding method such as IG.

[0008]

The first feature of the present invention is as follows.
An object of the present invention is to stably fix a long and large-sized structural portion such as a vehicle and perform friction welding. Therefore, the present invention can be achieved by the following means.

(1) The work fixing jig has a rotating mechanism.

(2) The jig for fixing a workpiece provided with a rotating mechanism is provided on the front side of the welding portion where the rotating tool is disposed or on the side opposite to the rotating tool (the back surface of the welded portion). Must be installed on one or both.

(3) The jig for fixing a workpiece provided with a rotation mechanism is one or both of the front and rear of the rotary tool.

(4) The work fixing jig provided with the rotation mechanism automatically moves in the vertical direction following the deformation of the work.

(5) The jig for fixing a workpiece provided with a rotating mechanism moves in a welding direction or a direction opposite to the welding direction in conjunction with movement of the rotating tool or independently.

Further, a second feature of the present invention is that: (6) welding of a long portion such as a vehicle is performed while monitoring the welding state during welding or the groove of the welded portion optically or electronically; It is desirable to do. Friction welding can be stably performed even on long parts.

(7) On the other hand, by the above-mentioned welding method,
Locally melting the front or back surface of the welded weld by an arc or plasma or laser heat source; Thereby, even if an unwelded portion is generated in the friction welded portion, it can be automatically repaired by the fusion welding.

(8) The thickness of the welded portion of the workpiece is locally higher (thicker) than other thicknesses. The increased thickness is desirably 0.3 mm or more and 2 mm or less. The width of the raised portion is preferably substantially the same as the outer shape of the rotary tool flange.

(9) Joining the work from both sides. This purpose can be achieved by welding from both sides simultaneously or at different times.

[Operation] The rotary tool which is the first feature of the present invention.
By providing a rotation mechanism on the workpiece fixing jig disposed on the side opposite to the tool, the workpiece can be moved with a small force. Further, the workpiece fixing jig provided with the rotation mechanism automatically moves in the vertical direction following the deformation of the workpiece. Therefore, even when the workpiece is deformed, the fixing jig does not separate from the workpiece. Therefore, generation of defects can be prevented, and highly reliable welding can be performed.

On the other hand, by locally increasing the thickness of the welded portion of the processed member, which is the second feature of the present invention, from the thickness of the other portions, the following effects can be expected.

In the present friction welding, the thickness of the joint is locally reduced due to the cutting effect of the rotating tool, the mechanical strength of the weld is reduced practically, and the reliability of the processed member is reduced. There's a problem. In order to prevent this, the above problem can be solved by locally increasing the thickness of the joint. Specifically, it is desirable that the thickness be 0.3 mm or more and 2 mm or less. Furthermore, according to the present invention, even when the gap at the joint is large, the gap can be compensated for at the portion where the thickness is locally increased, so that welding can be performed without defects. For example, if the joint structure is I
Welding can be performed without defects, not only in molds but also in molds or V-shapes.

[0021]

DESCRIPTION OF THE PREFERRED EMBODIMENTS [Embodiment 1] FIG. 1 shows a butt welding of a vehicle workpiece having a length of 20 m, a width of 1 m and a thickness of 4 mm made of an aluminum alloy. 2 shows a perspective view in which a total of five fixing jigs for the workpiece 2 provided with a rotating mechanism are arranged and welded on the opposite side, that is, on the back side of the welding surface. FIG. 2 is a sectional view showing details of the rotary tool 1 of FIG.

Hereinafter, embodiments of the present invention will be specifically described. In this welding method, welding is performed by inserting a rotary tool 1 into a welded portion 3 of a workpiece 2 for a vehicle and moving the rotary tool 1 in five directions while rotating the tool in four directions. In this welding method, first, the workpiece 2 is supported on the support 6. With only this support, the workpiece 2 is deformed by the load of the rotating tool, and cannot be stably welded. For this reason, fixing jigs 7 and 8 for fixing a workpiece are arranged on the side where the rotary tool 1 is arranged and on the opposite side thereof so as not to be deformed by the load of the rotary tool 1. In this case, the fixing jigs 7 and 8 are provided with a rotation mechanism. Further, as shown in FIG. 2, the fixing jigs 7 and 8 are attached to a supporting air mechanism 9 and have a structure that can automatically move up and down in conjunction with the up and down movement of the workpiece 2. The fixing jig provided with the rotating mechanism moves in conjunction with the movement of the rotating tool in the welding direction.

The rotary tool 1 is mounted on a motor 10,
It moves in five directions while rotating in four directions. The rotary tool 1 has a mechanism for automatically moving in the vertical direction following the deformation of the workpiece 2 in the vertical direction.

The shape of the rotary tool 1 in this embodiment is an M screw having a tip portion having a diameter of 5 mm and a length of 4 mm. Also,
The rotation speed is 1000 rpm and the moving speed is 500 mm / mi.
n.

As described above, the frictional resistance between the workpiece and the fixing jig is reduced by the workpiece fixing jig provided with the rotating mechanism and the vertical movement mechanism. For this reason, even when a workpiece such as a railway vehicle is long, it can be easily and stably fixed. Therefore, welding can be stabilized. By this welding, a high-speed vehicle was manufactured. In the embodiment, the work 2 is fixed, and the rotary tool 1 and the fixing jigs 7 and 8 are moved in the welding direction. .

[Embodiment 2] FIG. 3 shows a butt welding of a vehicle-made workpiece 2 having a length of 20 m, a width of 1 m, and a thickness of 5 mm made of an aluminum alloy. FIG. 2 is a perspective view showing a state in which fixing jigs 7 and 8 of a workpiece 2 provided with a total of seven rotation mechanisms are arranged and welded on the back side of the surface). The feature of this embodiment is that the jig for fixing the workpiece is arranged in front of the rotary tool 1 in the welding direction in addition to FIG. 1 of the first embodiment.

The welding fixes the workpiece 2 to the fixed base 6. Further, fixing jigs 7 and 8 for fixing the workpiece on the side where the rotary tool 1 is arranged and on the opposite side thereof are arranged so that the workpiece is not deformed by the load of the rotary tool 1. The fixing jigs 7 and 8 also have a structure that can automatically move up and down in conjunction with the rotation mechanism and the up and down movement of the workpiece. As described above, the frictional resistance between the workpiece and the support jig is reduced by the workpiece fixing jig provided with the rotation mechanism and the vertical movement mechanism. For this reason, even if the workpiece is a long vehicle structure, it can be easily and stably fixed. Therefore, welding can be stabilized.
The shape of the rotary tool and the welding conditions in this embodiment are the same as those in the first embodiment. By this welding, a high-speed vehicle was manufactured.

[Embodiment 3] FIG. 4 shows a work 2 for a vehicle made of an aluminum alloy and having a length of 25 m, a width of 0.5 m and a thickness of 4 mm.
FIG. 1 is a perspective view of a butt welding method in which a fixing jig for a workpiece 2 having a total of nine rotating mechanisms is arranged and welded on the side where the rotary tool 1 is arranged and on the opposite side (the back side of the welding surface). That is, the arrangement position of the fixing jig is characterized in that it is also arranged in front of the rotary tool on the welding back side in the welding direction in addition to FIG. 3 of the second embodiment.

In this welding method, the workpiece 2 is fixed to the support base 6 and the workpiece 2 is further placed on the opposite side of the rotary tool 1 so as not to be deformed by the load of the rotary tool 1. The supporting jigs 7 and 8 for supporting are arranged. In this case, the support jigs 7 and 8 are provided with a rotation mechanism.
Further, the support jigs 7 and 8 also have a structure that can automatically move up and down in conjunction with the up and down movement of the workpiece. Welding is performed by rotating the rotary tool in four directions and moving in five directions. In this case, the fixing jigs 7 and 8 also move in five directions in conjunction with the movement of the rotary tool.

In this embodiment, welding is performed while monitoring the welding condition on the back side of the welding by an optical monitoring device.

As described above, the frictional resistance between the workpiece and the support jig is reduced by the workpiece support jig provided with the rotation mechanism and the vertical movement mechanism. Therefore, even when the workpiece is long, it can be easily and stably fixed. Therefore, welding can be stabilized. Butt welding of aluminum alloy was performed. The shape of the rotary tool and the welding conditions are the same as in the first embodiment. By this welding, a high-speed vehicle was manufactured.

[Embodiment 4] FIG. 5 shows a vehicle-made workpiece 2 made of an aluminum alloy and having a length of 25 m, a width of 0.5 m and a thickness of 4 mm.
FIG. 1 is a perspective view of a butt-welding method in which a fixing jig for a workpiece 2 having a total of 11 rotation mechanisms is arranged and welded on the side where the rotary tool 1 is arranged and on the opposite side (the back side of the welding surface).
That is, the arrangement position of the fixing jig is characterized in that it is arranged not only in front of the rotary tool 1 on the welding back surface side but also behind, in addition to FIG. 3 of the second embodiment.

In this welding method, the workpiece 2 is fixed to the support base 6 and the workpiece 2 is further placed on the opposite side of the rotary tool 1 so as not to be deformed by the load of the rotary tool 1. The supporting jigs 7 and 8 for supporting are arranged. In this case, the support jigs 7 and 8 are provided with a rotation mechanism.
Further, the support jigs 7 and 8 also have a structure that can automatically move up and down in conjunction with the up and down movement of the workpiece. Welding is performed by rotating the rotary tool in four directions and moving in five directions. In this case, the fixing jigs 7 and 8 also move in five directions in conjunction with the movement of the rotary tool.

In the present embodiment, welding is performed while monitoring the welding conditions on the front and back surfaces of the welding by an electronic monitoring device using a CCD camera.

As described above, the frictional resistance between the workpiece and the support jig is reduced by the workpiece support jig provided with the rotation mechanism and the vertical movement mechanism. Therefore, even when the workpiece is long, it can be easily and stably fixed. Therefore, welding can be stabilized. Butt welding of aluminum alloy was performed. The shape of the rotary tool and the welding conditions are the same as in the first embodiment. By this welding, a high-speed vehicle was manufactured.

[Embodiment 5] FIG. 6 shows a welding method and apparatus for butt welding a work made of an aluminum alloy for a vehicle, in which a rotary tool 1 is arranged on both the front and back surfaces of a work 2 and welded from both the front and back surfaces. FIG. In this embodiment, the rotary tool 1 is also arranged on the opposite side of the workpiece (the back side of the welding), and the fixing jig is also arranged on the rear side of the rotary tool with respect to the welding direction. It is characteristic.

FIG. 7 is a sectional view of the rotary tool 1 shown in FIG. The rotary tool 1b is also disposed on the back surface of the welded portion, and the weight of the rotary tool 1a disposed on the front side is adjusted by the rotary tool.
1b. In this welding method, first, the workpiece 2 is supported on the support 6. With only this support, the workpiece 2 is deformed by the load of the rotating tool, and cannot be stably welded. For this reason, a total of four fixing jigs 7 and 8 for fixing a workpiece are arranged on the side where the rotary tool 1 is arranged and on the opposite side so as not to be deformed by the load of the rotary tool 1. In this case, the fixing jigs 7 and 8 are provided with a rotation mechanism. Further, as shown in FIG. 7, the fixing jigs 7 and 8 are attached to a supporting air mechanism 9 and have a structure capable of automatically moving up and down in conjunction with the up and down movement of the workpiece 2. In addition, fixing jigs 7 and 8 provided with this rotation mechanism
Moves in conjunction with the movement of the rotary tool 1 in the welding direction.

As shown in FIG. 7, the rotary tool 1 is attached to a motor 10 and is moved in five directions while rotating in four directions to be welded.

As shown in FIG. 7, the feature of the present embodiment is that the thickness of the welded portion of the workpiece is locally increased by 0.8 mm. Thus, even when a dent is formed on the surface of the welded portion due to friction between the rotating tool and the processed portion, the welded portion is thickened, so that a decrease in mechanical strength can be prevented.

As described above, the frictional resistance between the workpiece and the fixing jig is reduced by the workpiece fixing jig provided with the rotating mechanism and the vertical movement mechanism. For this reason, even if the workpiece is long and large like a railway vehicle, it can be easily and stably fixed. Therefore, a long workpiece such as a vehicle can be stably welded. The shape of the rotary tool and the welding conditions are the same as in the first embodiment. By this welding, a high-speed vehicle was manufactured.

[Embodiment 6] FIG. 8 is a sectional view showing a method of welding a honeycomb panel (hollow shaped member) of a railway vehicle manufactured by extrusion. This honeycomb panel is
The length is 25 m, the width is 0.4 m, and the thickness is 50 mm. The honeycomb panel includes a face plate 12, a core material 13, and an edge material 14. The honeycomb panel is disposed on the support base 6 and further fixed by fixing jigs 7 and 8 from above and below. In welding, the rotary tool 1 is inserted into the joint of the rim member 14, and the workpieces are solid-phase joined from both sides. That is,
Since the present welding method does not melt, the molten metal does not drip downward due to the gravity of the molten metal. For this reason, welding is performed by rotating the upper and lower parts of the honeycomb panel 6 at the edge member 6.
1 was inserted. The rotary tool 1 is attached to the robot 11, moves in the direction of the welding line while rotating by the driving force of the motor 10, and solidifies the workpieces.
The rotary tool 1 can be automatically moved in the vertical direction according to the deformation of the workpiece surface. Further, the rotary tool 1 can be automatically moved in the left-right direction along the welding line. This embodiment is characterized in that the height of the face plate at the joint portion is locally higher by about 0.8 mm than other portions. Thus, even when a dent is formed on the surface of the welded portion due to friction between the rotating tool and the processed portion, the welded portion is thickened, so that a decrease in mechanical strength can be prevented.

FIG. 9 is a perspective view of a railway vehicle structure manufactured by the above method. FIG. 10 shows the appearance of a railway vehicle produced by further welding a plurality of the structures shown in FIG. Joint 3
Although the length is partly 12.5 m, a maximum length of 25 m is formed from the front and back surfaces.

[Structure of the Present Invention] The structure of the present invention is achieved by at least one of the following. (1) A rotary tool made of a material harder than the material of the vehicle structural body and the vehicle body Railway vehicle structure solid-phase-welded by frictional heat with a weld (2) The vehicle structure welded by the solid-phase welding method is one or both of the front surface side and the rear surface side of the weld portion To be fixed and welded by a fixing jig with a rotating mechanism.

(3) The rotary tool is disposed at one or both of the front and the rear of the rotary tool.

(4) The fixing jig is a rotary tool.
To move up and down independently or in conjunction with up and down movement or left and right.

(5) The railway vehicle is joined from both front and back. (6) The thickness of the joint is made thicker than other portions.

[0047]

According to the present invention, a workpiece can be solid-phase welded even in a long and large structure such as a railway vehicle, that is, welding can be performed without melting the workpiece. Therefore, a large-sized structure such as a railway vehicle can be manufactured with higher precision and at lower cost than before. In addition, by increasing the thickness of the joining portion compared to other portions, joining can be performed without defects even when the gap at the joining portion is large. Furthermore, by joining from both the front and back surfaces, a workpiece and a structure composed of the workpiece can be manufactured efficiently.

[Brief description of the drawings]

FIG. 1 is a perspective view of a friction welding apparatus according to an embodiment of the present invention.

FIG. 2 is a longitudinal sectional view of the apparatus of FIG.

FIG. 3 is a perspective view of a friction welding device according to another embodiment.

FIG. 4 is a perspective view of a friction welding device according to another embodiment.

FIG. 5 is a perspective view of a friction welding device according to another embodiment.

FIG. 6 is a perspective view of a friction welding device according to another embodiment.

7 is a longitudinal sectional view of the device of FIG.

FIG. 8 is a perspective view of a friction welding device according to another embodiment.

FIG. 9 is a perspective view of a structure of a railway vehicle.

FIG. 10 is a perspective view of a railway vehicle.

[Explanation of symbols]

1: Rotary tool, 2: Workpiece, 3: Weld, 7, 8: Roller.

Continued on the front page (72) Inventor Akihiro Sato 7-1-1, Omika-cho, Hitachi City, Ibaraki Prefecture Inside Hitachi, Ltd.Hitachi Research Laboratories (72) Inventor Kinya Aota 794, Higashi-Toyoi, Kudamatsu-shi, Yamaguchi Prefecture Inside the Hitachi Kasado Factory (72) Inventor Masakuni Esumi 794, Higashi-Toyoi, Kazamatsu City, Yamaguchi Prefecture Inside the Hitachi Kasado Factory (72) Inventor Yasuo Ishimaru 794, Higashi Toyoi, Kudamatsu City, Yamaguchi Prefecture, Japan Inside the Hitachi Kasado Plant

Claims (2)

[Claims] 1. A friction welding apparatus for moving a rotary tool while rotating the tool while inserting the rotary tool into the workpiece, the mechanism including a mechanism for vertically moving the rotary tool following a vertical deformation of the workpiece. A friction welding apparatus, characterized in that: 2. The friction welding apparatus according to claim 1, further comprising a fixing jig provided with a rotation mechanism for contacting a workpiece in front of or behind the rotary tool.