JP3311590B2 - Friction welding method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a friction welding method using a rotary tool, and relates to the manufacture of all structures such as automobiles, ships, aviation, elevators, pressure vessels, etc., in addition to vehicle structures made of aluminum alloy. Available to

[0002]

2. Description of the Related Art As a friction welding method, Japanese Patent Application Laid-open No.
In 090, JP-tree consists substantially rigid material than the workpiece - Le inserted into the welding portion of the workpiece, said, tool - by moving while rotating the Le, 該回 Utatetsu - le and processing BACKGROUND ART A welding method for friction-welding a workpiece by plastic flow due to frictional heat generated between the workpiece and the workpiece is known.

[0003] In contrast to the conventional friction welding method in which workpieces are rotated and the workpieces are welded by frictional heat, Japanese Patent Publication 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
Rotation tool according 5090 JP - Le inserted into the workpiece, 該回 Utatetsu - elongated in a friction welding method of welding by moving while rotating the Le like vehicle structure and construction of a large When applied to, there are the following problems.

(1) The workpiece is deformed during welding due to the load of the rotating tool. For this reason, it is necessary to fix the workpiece being welded from the front, back, side or side directions of the workpiece so as to withstand the force of the rotating tool. In particular, 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.

An object of the present invention is to enable reliable friction welding even when a workpiece is deformed.

[0009]

The above object is achieved by inserting a rotary tool made of a material substantially harder than the material of a workpiece into a joint of the workpiece and moving the rotary tool while rotating the rotary tool. In the friction welding method using frictional heat, the right and left sides in the moving direction of the rotary tool are
With the rollers arranged on the front and back sides of the workpiece
In, moving the roller up and down direction in association with the vertical direction of the deformation of the workpiece caused by weight of the rotary tool, the achievable.

[Operation] The rotary tool and the rotary tool follow the vertical deformation of the workpiece.
Since the roller and the roller are moved in the vertical direction, highly reliable friction welding can be performed even when the workpiece is deformed.

[0011] The friction welding, rotary tool - by Le cutting effect, the thickness of the joint is locally thinned, ruled mechanical strength of the weld low, a problem in terms of reliability of the workpiece is there.
In order to prevent this, the above problem can be solved by locally increasing the thickness of the joint. In particular,
0.3 mm or more and 2 mm or less are desirable. Further, according to the present invention, even when the gap of the joint is large,
Welding can be performed without defects because the gap is compensated for in the area where the thickness is locally increased. For example, welding can be performed without defects even if the joint structure is not only the I type but also the L type or the V type.

[0012]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiment 1 FIG. 1 shows a 20 m long, 1 m wide and 4 mm thick aluminum alloy.
mm butt welding of vehicle workpieces, the side on which the rotary tool 1 is disposed (the surface side of the weld) and the opposite side, that is,
A perspective view is shown in which a total of five fixing jigs for the workpiece 2 having a rotation mechanism are arranged on the back side of the welding surface and welding is performed. FIG. 2 shows FIG.
FIG. 3 is a cross-sectional view showing details of a part of the rotary tool 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, the rotary tool 1
Fixing jigs 7 and 8 for fixing the workpiece are arranged on the side where the rotating tool 1 is arranged and on the side opposite to the side where the rotating tool 1 is not deformed by the load . In this case, the fixing jigs 7 and 8 are provided with a rotation mechanism. Further, the fixing jigs 7 and 8 are shown in FIG.
As shown in (1), there is also provided a structure which is attached to the support mechanism 9 and which can automatically move up and down in conjunction with the up and down deformation 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 according to the present 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 rotation 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 length 20 m, a width 1 m, and a thickness 5 of an aluminum alloy.
In the butt welding of the work 2 for a vehicle having a diameter of 7 mm, a total of 7
The perspective view which arranges and fixes the fixing jigs 7 and 8 of the workpiece 2 provided with the rotation mechanism of FIG. In this embodiment, the jig for fixing the workpiece is a rotary tool in addition to FIG.
It is characterized in that it is also arranged forward of the welding direction of the nozzle 1.

The workpiece 2 is fixed to a fixing table 6. further,
Fixing jigs 7 and 8 are provided on the side of the rotating tool 1 and on the opposite side so that the workpiece is not deformed by the load of the rotating tool 1. The fixing jig 7
And 8 also have a rotating mechanism and a structure that can automatically move up and down in conjunction with the up and down movement of the workpiece. As described above, the frictional resistance between the workpiece and the fixing 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 butt welding of a vehicle 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. The perspective view which arranges and welds the fixing jig of the workpiece 2 provided with a total of nine rotation mechanisms on the back side of the welding surface) is shown. In other words, the position of the fixing jig is different from that of FIG.
The feature is that it is also arranged in front of the welding direction of the metal.

In this welding method, the workpiece 2 is fixed to the support base 6, and the workpiece is supported 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. Fixing jigs 7 and 8 are arranged. In this case, the fixing jigs 7 and 8 are provided with a rotation mechanism. Further, the fixing 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 supporting jig is reduced by the workpiece fixing 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 butt welding of a vehicle 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. The perspective view which arranges and welds the fixing jig of the workpiece 2 provided with 11 rotation mechanisms in total on the back side of the welding surface) is shown. In other words, the position of the fixing jig is different from that of FIG.
It is characterized in that it is arranged at the front as well as the rear of the shell 1.

In this welding method, the workpiece 2 is fixed to the support base 6, and the workpiece is supported on the side where the rotary tool 1 is disposed and on the opposite side so as not to be deformed by the load of the rotary tool 1. Fixing jigs 7 and 8 are arranged. In this case, the fixing jigs 7 and 8 are provided with a rotation mechanism. Further, the fixing 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 condition on the front and back sides 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 fixing 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 (the back side of the welding) of the workpiece, and the fixing jig is also arranged on the front 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 on the side where the rotary tool 1 is arranged and on the opposite side thereof are arranged so as not to be deformed by the load of the rotary tool 1. I do. 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 support 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. 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 the motor 10 and is moved in five directions while rotating in four directions to be welded.

As shown in FIG. 7, the feature of this embodiment is that the thickness of the welded portion of the workpiece is locally increased by 0.8 mm. Thus, the rotation tool - le and pressure
Since the welded portion even when the dent is formed on the surface of the welded portion due to friction with the engineering product is thicker, it is possible to prevent deterioration of mechanical strength.

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 cross-sectional view showing a method of welding a honeycomb panel (hollow shaped material) of a railway vehicle manufactured by extrusion. This honeycomb panel has a length of 25 m, a width of 0.4 m,
The thickness is 50 mm. This honeycomb panel has a face plate 1
2, the core member 13 and the edge member 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 on the edge material 6 of the honeycomb panel.
The rotary tool 1 was inserted from above and below into the part.
該回 Utatetsu - le 1 is attached to the robot 11, mode - Move to the welding line direction while rotating with the driving force by the motor 10,
The workpieces are solid-phase bonded. Incidentally, 該回 Utatetsu - le 1,
Movement can be automatically controlled in the vertical direction according to the deformation of the workpiece surface. Furthermore, 該回 Utatetsu - le 1 may automatically move the control in the lateral direction along the weld line. In this example,
The feature is that the height of the face plate at the joint is locally higher by about 0.8 mm than other portions. Accordingly, even when a recess is formed on the surface of the welded portion due to friction between the rotating tool and the workpiece, 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 both front and back surfaces .

[0034]

According to the present invention, since the rotary tool and the rollers are moved in the vertical direction following the vertical deformation of the workpiece caused by the weight of the rotary tool, the reliability is maintained even when the workpiece is deformed. High friction welding can be performed.

[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.

──────────────────────────────────────────────────続 き Continued on front page (72) Inventor Kinya Aota 794, Higashi-Toyoi, Kazamatsu, Kudamatsu-shi, Yamaguchi Prefecture Inside the Kasado Plant of Hitachi, Ltd. In the Kasado Plant (72) Inventor Yasuo Ishimaru 794, Higashi-Toyoi, Kazamatsu City, Yamaguchi Prefecture In the Kasado Plant, Hitachi, Ltd. (56) References JP 1-197088 (JP, A) JP 6-A 246469 (JP, A) Table 7-505090 (JP, A) (58) Fields surveyed (Int. Cl. ⁷ , DB name) B23K 20/12

Claims (2)

(57) [Claims] 1. A friction welding method utilizing frictional heat generated by inserting a rotating tool made of a material substantially harder than the material of a workpiece into a joint of the workpiece and moving the rotating tool while rotating the rotating tool. In the right and left of the moving direction of the rotating tool , the workpiece
On the surface side and back surface side in the state in which the rollers, friction welding method, characterized in, moving upward under direction in conjunction with the roller in the vertical direction of the deformation of the workpiece caused by weight of the rotary tool. 2. The rotary tool according to claim 1, wherein a front surface or a rear surface of the workpiece in front of or behind the rotary tool is fixed by a fixing jig provided with a rotating mechanism, and the fixing jig is weighted by the rotating tool. And moving the workpiece in the vertical direction in conjunction with the vertical deformation of the workpiece caused by the friction welding.