【作者】 孙龙；

【导师】 朱海；

【作者基本信息】 东北林业大学 ， 机械电子工程， 2018， 硕士

【摘要】 搅拌摩擦焊作为一种先进的固相连接技术,为有色金属板材的焊接提供了一种优于熔焊的连接工艺,在轻量化结构的焊接中具有明显优势。搅拌摩擦焊设备是类似于数控铣床的机械,但在价格上远远高于数控铣床。本研究在分析了薄板铝合金搅拌摩擦焊过程中产生的机械载荷,基于批量生产的数控铣床结构,探索降低制造成本的轻型搅拌摩擦焊设备的方法,本研究有助于推进搅拌摩擦焊技术在更宽领域的应用。利用立式铣床设计和进行3mm厚6061-T6铝合金板的搅拌摩擦焊的工艺和机械载荷试验,通过改变搅拌头转速、焊接速度、轴肩下压量与主轴倾角,研究不同参数对焊缝表面成形情况、焊缝力学性能的影响,确定合适的焊接参数窗口。在该窗口下,测得搅拌头在焊接过程中承受的轴向力和径向力,通过理论计算得到搅拌头所受扭矩,搅拌针承受的轴向力和摩擦扭矩,进而确定轻型搅拌摩擦焊机的主轴所承受轴向力和径向力及最大扭矩等基本参数,为轻型搅拌摩擦焊机的结构设计提供基础。总结和分析目前搅拌摩擦焊机的结构形式,及搅拌摩擦焊机各运动轴的要求,根据试验得到的基本参数,确定适用于3mm厚以下的铝合金板轻型搅拌摩擦焊机的总体方案。采用结构和尺寸相近的数控铣床的床身、立柱和工作台,和自主设计主轴组件,主轴箱、连接架等部件相结合,有效降低主机的制造成本和周期。依据主轴所承受轴向力和径向力及最大扭矩等基本参数完成自主设计部件的三维设计,并完成整机装配。该机通过调整主轴箱位置的可手动调节的旋转轴A轴,主轴可调节±5 °的倾角;通过添加数控旋转台,还可焊接平面圆形或曲线焊缝。基于焊接过程,分析轻型搅拌摩擦焊机的受力情况,确定受力的主要零部件及受力部位,运用ANSYS软件对主要受力零部件进行有限元分析,由应力和位移图等分析结果判断其可靠性;同时,对主轴进行了模态分析,确定了主轴各阶的频率和振型,进一步验证主轴设计的正确性。由焊接过程可知主轴部位的运动为主要运动,其运动决定焊接的结果,故运用Adams对主轴部件进行运动仿真,由运动分析的结果判断主轴部件的可行性和机械系统的性能。更多还原

【Abstract】 Friction stir welding,as an advanced solid-phase connection technology,provides a superior welding process for the welding of non-ferrous metal plates,and has obvious advantages in the welding of lightweight structures.Friction stir welding equipment is a machine similar to a CNC milling machine but is far more expensive than a CNC milling machine in terms of price.This study analyzed the mechanical load generated during the friction stir welding of thin-plate aluminum alloys.Based on the mass-produced CNC milling machine structure,it explored a method to reduce the manufacturing cost of light friction stir-friction welding equipment.This study helps to promote friction stir welding technology.Wider applications.Using vertical milling machine design and 3mm thick 6061-T6 aluminum alloy plate friction stir welding process and mechanical load test,by changing the speed and speed of the stirring head,welding speed,shoulder shoulder pressure and the inclination of the spindle,study different parameters butt welding the surface forming conditions of the joints and the influence of the mechanical properties of the welds determine the appropriate welding parameter window.Under this window,the axial and radial forces of the stirrer head during the welding process were measured.The torque received by the stirrer head,the axial force and the frictional torque of the stirrer needle were determined by theoretical calculations,and the light-weight friction stir welding was determined.The basic parameters such as axial force,radial force and maximum torque that the machine’s main shaft bears provide the basis for the structural design of the lightweight friction stir welding machine.Summarize and analyze the current structure of the friction stir welding machine and the requirements of each axis of the friction stir welding machine.Based on the basic parameters obtained from the experiment,the overall scheme of the aluminum alloy plate light friction stir welding machine below 3 mm thick is determined.The base,bed and workbench of CNC milling machines with similar structures and dimensions are combined with independently designed spindle components,spindle boxes,and connecting frames to effectively reduce the manufacturing cost and cycle time of the host.The three-dimensional design of the self-designed components was completed based on the basic parameters such as the axial force,radial force and maximum torque that the main shaft can bear,and the complete machine assembly was completed.The machine can adjust the tilting angle of the spindle by adjusting the position of the spindle box.The spindle can adjust the tilt angle of the spindle.By adding a numerically controlled rotating table,it can also weld flat circular or curved welds.Based on the welding process,the force of the light friction stir welding machine is analyzed to determine the main components and the force parts.The finite element analysis is performed on the main force components using ANSYS software,and the results are analyzed by stress and displacement maps.Its reliability;from the welding process can be seen as the main part of the main axis of the movement,its movement determines the results of the welding,so the use of Adams on the spindle component movement simulation,from the results of the movement analysis to determine the feasibility of the spindle components and mechanical system performance.更多还原