CN114659693A - Device and method for detecting fracture failure of friction stir welding tool - Google Patents
Device and method for detecting fracture failure of friction stir welding tool Download PDFInfo
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- CN114659693A CN114659693A CN202210512708.XA CN202210512708A CN114659693A CN 114659693 A CN114659693 A CN 114659693A CN 202210512708 A CN202210512708 A CN 202210512708A CN 114659693 A CN114659693 A CN 114659693A
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
- G01L5/00—Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes
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- 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
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- 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
- B23K20/26—Auxiliary equipment
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
- G01L3/00—Measuring torque, work, mechanical power, or mechanical efficiency, in general
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Abstract
The invention relates to an online detection device for fracture failure of a friction stir welding tool and a method for detecting fracture failure by using the device. The invention provides a device capable of judging whether a stirring tool is broken or not in a static shaft shoulder friction stir welding process in real time on line and a method for detecting by using the device, so that on one hand, the workload of operators is reduced, on the other hand, the device can prompt in time when a needle is broken, and unnecessary economic loss is avoided. The invention discloses a device for detecting the fracture and failure of a friction stir welding tool, which comprises a machine head, wherein a main shaft connected with a motor is arranged in the machine head, a fixed static shaft shoulder is arranged on the machine head, a stirring tool is arranged on the main shaft, and the stirring tool extends out of a through hole on the static shaft shoulder, and the device is characterized in that: a pressure sensor and a torque sensor are arranged between the main shaft and the motor and connected with a detection module.
Description
Technical Field
The invention relates to an online detection device for fracture failure of a friction stir welding tool and a method for detecting fracture failure by using the device. More particularly, the device and the method for detecting the breakage and the failure of the stirring tool in the friction stir welding of the static shaft shoulder in real time.
Background
The static shaft shoulder friction stir welding is developed on the basis of the traditional friction stir welding, and in the welding process, the static shaft shoulder only slides on the surface of a sample to be welded and does not rotate at a high speed along with a stirring tool. The static shaft shoulder friction stir welding has the advantages that the upper surface of a welding seam is formed excellently, the characteristics of the conventional friction stir welding seam such as flash and arc lines are avoided, the symmetry of the structure and the performance of the advancing side and the retreating side is good, the performance after welding is excellent, the heat input during welding is less, and the deformation of a sample after welding is relatively small.
At present, the static shaft shoulder friction stir welding technology is widely applied to the fields of aerospace, new energy vehicles, high-speed trains and the like, and particularly in the production of new energy vehicle battery trays, because after static shaft shoulder friction stir welding, no flash exists at the welding seam, manual polishing after welding is not needed, and deformation after welding is small. The application of the technology shortens the production flow of the battery tray, improves the production efficiency, and becomes the mainstream process technology for producing and manufacturing the battery tray of the new energy automobile.
Due to the split structure design of the static shaft shoulder and the stirring tool in the static shaft shoulder friction stir welding process, the stirring tool is generally in a slender cylinder form, and the stirring tool bears larger upsetting force, lateral force and advancing resistance in the whole welding process, so that fracture failure is easily caused; and because static shaft shoulder is at the flat push effect of whole course of working, the churning tool fracture is difficult to follow the upper surface discovery of welding seam, in automated production, only after the welding is finished through artifical observation churning tool after, can learn whether this churning tool breaks.
And in the automatic continuous production process, whether the stirring tool is broken or not can not be observed manually after each part is produced, then the production of the next part is started, the production rhythm can not meet the processing beat requirement of mass products, the workload and the working strength of operators are increased by manual observation and judgment, and meanwhile, if static shaft shoulder stirring friction welding is carried out, the stirring tool is not found timely after being broken, the product processing production is continued, so that all subsequent processed products can be scrapped, and great economic loss is brought.
Disclosure of Invention
The invention aims at the problems and provides a device capable of judging whether a stirring tool is broken or not in a static shaft shoulder friction stir welding process in real time on line and a method for detecting by using the device, so that on one hand, the workload of operators is reduced, on the other hand, the device can prompt in time when a needle is broken, and unnecessary economic loss is avoided.
In order to achieve the above object, the present invention adopts the following technical scheme, and the device for detecting the breakage failure of the friction stir welding tool comprises a machine head, wherein a main shaft connected with a motor is arranged in the machine head, a fixed static shaft shoulder is arranged on the machine head, a stirring tool is arranged on the main shaft, and the stirring tool extends out of a through hole on the static shaft shoulder, and is characterized in that: a pressure sensor and a torque sensor are arranged between the main shaft and the motor and connected with a detection module.
In a preferred embodiment of the present invention, the pressure sensor is disposed above the head for detecting a pressure applied to the head, the pressure being equal to and opposite to an upsetting force applied to the welding material by the stationary shoulder and the stirring tool.
As another preferable scheme of the present invention, the torque sensor is connected to the output shaft of the motor, and is configured to measure the torque value of the output shaft of the motor in real time to reflect the torque applied to the stirring tool.
As a third preferred aspect of the present invention, the detection module reads the value of the pressure sensor and the value of the torque sensor in real time, a fracture detection and determination program is built in the detection module, and by setting a corresponding pressure change threshold and a corresponding torque change threshold, when the fracture detection and determination program is triggered, the stirring tool fracture detection module sends a fracture alarm message of the stirring tool.
The invention discloses a method for detecting the fracture failure of a friction stir welding tool, which is characterized by comprising the following steps: the method comprises the following steps:
step one, determining the size of the corresponding static shaft shoulder and the through hole on the static shaft shoulder, the length of the stirring tool corresponding to the through hole and the diameter of the stirring tool according to the material and thickness parameters of the welding material.
Step two, setting an acting force criterion F in the detection module according to the rotating speeds of the static shaft shoulder, the stirring tool and the main shaft during welding, the welding feeding speed and the set value of the welding pressurethresholdCriterion T of sum torquethreshold。
And step three, when the set feeding speed is reached, the detection module starts to work.
And step four, the detection module collects the acting force of the welding material measured by the pressure sensor applied to the stirring tool, then calculates the difference value of the previous sampling period and the next sampling period of the acting force, and divides the value of the previous sampling period after taking the absolute value to obtain the value delta F of the change rate of the acting force.
And step five, the detection module collects the numerical value of the main shaft motor torque measured by the main shaft motor torque sensor, then calculates the difference value of the previous sampling period and the next sampling period obtained by the torque sensor measurement, and divides the numerical value of the previous sampling period after taking the absolute value to obtain the numerical value Delta T of the change rate.
Step six, comparing the calculated delta F and delta T with a set value,
when Δ F> FthresholdAnd Δ T> TthresholdWhen the temperature of the water is higher than the set temperature,
the detection module judges that the stirring tool is broken at the moment, and the stirring tool breakage detection module sends out alarm warning information; when the delta F and the delta T do not accord with the criterion, the program continues to run and the parallel comparison calculation is carried out until the welding is finished.
As a preferable scheme of the detection method for the fracture failure of the friction stir welding tool, the detection module revises an acting force criterion F according to delta F and delta TthresholdCriterion T of sum torquethreshold(ii) a Criterion of acting force FthresholdAnd torqueCriterion T ofthresholdThe specific values of (a) gradually approach to (Δ F) and (Δ T).
As another preferable aspect of the method for detecting the fracture failure of the friction stir welding tool according to the present invention, the detection module determines that the fracture occurs in the friction stir welding tool, and forms a log file of "fracture time-fracture event".
The invention has the beneficial effects that: the method has the advantages that whether the friction stir welding tool is broken or failed can be detected in real time, and meanwhile, the judgment method can judge the acting force criterion F along with the increase of data quantitythresholdCriterion T of sum torquethresholdThe accuracy of the criterion is continuously improved, so that the accuracy of the criterion is also continuously improved, the machine learning capability is realized, and the possibility of detection errors is reduced.
Drawings
Fig. 1 is a schematic structural view of the present invention.
Fig. 2 is a schematic view of the stationary shoulder.
Fig. 3 is a schematic view of the structure of the stirring tool.
In the attached drawing, 1 is a machine head, 2 is a static shaft shoulder, 3 is a stirring tool, 4 is a pressure sensor, 5 is a torque sensor, 6 is a detection module, 7 is welding material and 501 is a motor.
Detailed Description
The invention discloses a device for detecting breakage and failure of a friction stir welding tool, which comprises a machine head 1, wherein a main shaft connected with a motor 501 is arranged in the machine head 1, a fixed static shaft shoulder 2 is arranged on the machine head 1, a stirring tool 3 is arranged on the main shaft, and the stirring tool 3 extends out of a through hole on the static shaft shoulder 2, and the device is characterized in that: a pressure sensor 4 and a torque sensor 5 are arranged between the main shaft and the motor 501, and the pressure sensor 4 and the torque sensor 5 are connected with a detection module 6.
The handpiece 1 can be in the form of an electric spindle integrating the drive of the motor 501 and the transmission of the spindle, and can also be in the form of a mechanical spindle integrating the drive of the motor 501 and the transmission of the spindle.
The static shaft shoulder 2 is bowl-shaped, the bottom of the static shaft shoulder is provided with a through hole, and the diameter of the through hole is DShaft shoulderThe upper end surface of the static shaft shoulder 2 is arranged below the main shaftThe end faces are connected through screws, and the through holes at the bottom are used for installing the stirring tools 3.
The diameter of the through hole corresponding to the static shaft shoulder 2 of the stirring tool 3 is dStirring toolThe upper end of the stirring tool 3 is connected with a main shaft in the machine head 1 and rotates along with the rotation of the main shaft, and the lower end of the stirring tool 3 passes through a through hole at the lower end of the static shaft shoulder 2 and extends out of the through holeDepth of fieldThe long, stirring tool 3 cooperates with the stationary shoulder 2 to perform the function of friction stir welding of the stationary shoulder 2, generally dStirring tool= DShaft shoulder-0.5mm。
The pressure sensor 4 is installed above the spindle to detect the magnitude of the reaction force of the upsetting force applied to the welding material 7 by the stirring tool 3 and the stationary shoulder 2, which is transmitted to the detection module 6 through a data wire.
The torque sensor 5 is used to measure the torque value of the motor 501 of the spindle, the stirring tool 3, which is in rotational motion, and the value is transmitted to the detection module 6 through a data wire.
The detection module 6 reads the values of the pressure sensor 4 and the torque sensor 5 in real time, performs noise reduction and normalization processing on the values, performs calculation on corresponding data and performs fracture program detection by a built-in fracture detection judgment program, and when a fracture criterion is met, the fracture detection module 6 of the stirring tool 3 sends fracture alarm information.
According to a preferred embodiment, the welding material 7 can be an aluminum alloy, a magnesium alloy, a copper alloy, or the like, or can be a titanium alloy, a steel, or the like, and the thickness d of the welding material 7 isThickness of materialIn general, dThickness of material=lDepth of field+0.6～0.8mm；
The invention discloses a method for detecting the fracture failure of a friction stir welding tool, which comprises the following implementation steps of: (a) according to the material and thickness d of the welding material 7Thickness of materialIsoparametric, determining the corresponding stationary shoulder 2 and through hole DShaft shoulderAnd l of the stirring tool 3 corresponding to the through-holeDepth ofAnd dStirring tool。
(b) According to the static shaft shoulder 2, the stirring tool 3 andspindle rotation speed omega during welding, feed speed v of welding, and set value F of welding pressureUpsetting forceCorresponding acting force criterion F is arranged in the breaking detection module 6 of the stirring tool 3thresholdCriterion T of sum torquethreshold；
(c) When the set feeding speed v is reached, the stirring tool 3 breakage detection module 6 starts to work;
(d) the detection module 6 is used for carrying out noise reduction and normalization processing on the acting force applied to the stirring tool 3 by the welding material 7 measured by the pressure sensor 4, calculating the difference value of the previous sampling period and the next sampling period on the acting force in a fracture detection judgment program, and dividing the absolute value by the value of the previous sampling period to obtain the value of the change rate of the absolute value; specifically, the upsetting force value of n sampling periods is F1 ，F2 ，F3 ，F4 ，F5 …Fn-1 ，FnSoftware within the module automatically calculates Δ F for the data, such as:
△F1=|F2-F1|/F1，
△F2=|F3-F2|/F2，
△F3=|F4-F3|/F3、
△Fn-1=|Fn-Fn-1|/Fn-1；
(e) the stirring tool 3 fracture detection module 6 performs noise reduction on the numerical value of the torque of the spindle motor 501 measured by the torque sensor 5 of the spindle motor 501, after normalization processing, a fracture detection judgment program performs difference calculation on a previous sampling period and a next sampling period obtained by measurement of the torque sensor 5, and divides the numerical value of the previous sampling period after taking an absolute value to obtain a numerical value of the change rate of the sampling period. The torque values in n sampling periods are respectively T1，T2，T3，T4，T5……TnThe software in the module automatically calculates the data as delta T:
△T1=|T2-T1|/F1，
△T2=|T3-T2|/T2，
△T3=|T4-T3|/T3、
△Tn-1=|Tn-Tn-1|/Tn-1；
(f) comparing the calculated delta F and delta T with a set value,
when Δ Fn-1>FthresholdAnd Δ T n-1>TthresholdWhen the temperature of the water is higher than the set temperature,
when the module judges that the stirring tool 3 is broken at the moment, the breakage detection module 6 of the stirring tool 3 sends out alarm warning information and forms a log file of 'breaking time-breaking event'; when the delta F and the delta T do not accord with the criterion, the program continues to run and the parallel comparison calculation is carried out until the welding is finished.
The welding material 7 is mainly made of aluminum alloy materials, and can also be made of magnesium alloy, copper alloy, titanium alloy, steel and the like.
When the welding material 7 is an aluminum alloy, the thickness of the welding material 7 ranges from 0.5mm to 110 mm. Preferably, the welding thickness range of the aluminum alloy material is 0.5-30mm
The welding may be in the form of butt joints, lap joints, butt lap joints or corner joints.
The pressure sensor 4 is generally a pull-press type sensor capable of measuring unidirectional force, the output signal is in a 4-20 mA current form, the zero point is 12mA, the range of 4-12 mA is tensile stress, the range of 12-20 mA is compressive stress, the comprehensive error is not more than +/-0.1 (% FS), the linear error is not more than +/-0.1 (% FS), and the sampling period is 0.02s;
the output signal of the torque sensor 5 of the spindle motor 501 can be a voltage signal of 1-5V, a current signal of 4-20 mA and a frequency signal of 5-10-15 kHz, the measuring range is 0.005-20000 N.m, the measuring precision is not more than +/-0.5 (% FS), the nonlinear precision is not more than +/-0.2 (% FS), and the sampling period is 0.02s;
the criterion F built in the breaking detection module 6 of the stirring tool 3thresholdAnd TthresholdThe values being obtained by machine learning automatic calculationTaking, as the data volume increases, FthresholdAnd TthresholdThe accuracy of the criterion is continuously improved, so that the accuracy of the criterion is also continuously improved.
The measuring device and the method can be used on gantry type friction stir welding equipment and can also be used on serial and parallel robot friction stir welding equipment.
The time-event log file produced by the stirring tool 3 fracture detection module 6 is matched with a model of a welded product to realize graphical display of the fracture position of the stirring tool 3 on the model of the product.
It should be understood that the detailed description of the present invention is only for illustrating the present invention and is not limited by the technical solutions described in the embodiments of the present invention, and those skilled in the art should understand that the present invention can be modified or substituted equally to achieve the same technical effects; and are within the scope of the present invention as long as the requirements of use are met.
Claims (7)
1. The utility model provides a detection apparatus for friction stir welding instrument fracture became invalid, includes aircraft nose (1), is provided with the main shaft that links to each other with motor (501) in aircraft nose (1), is provided with fixed static shaft shoulder (2) on aircraft nose (1), be provided with stirring tool (3) on the main shaft, through-hole that stirring tool (3) were gone up by static shaft shoulder (2) stretches out its characterized in that: a pressure sensor (4) and a torque sensor (5) are arranged between the main shaft and the motor (501), and the pressure sensor (4) and the torque sensor (5) are connected with a detection module (6).
2. The apparatus for detecting a failure to break in a friction stir welding tool of claim 1, wherein: the pressure sensor (4) is arranged above the machine head (1) and used for detecting the pressure applied to the machine head (1), and the pressure and the upsetting force applied to the welding material (7) by the static shaft shoulder (2) and the stirring tool (3) have the same value and opposite directions.
3. The apparatus for detecting a failure to break in a friction stir welding tool of claim 1, wherein: the torque sensor (5) is connected with an output shaft of the motor (501) and used for measuring the torque value of the output shaft of the motor (501) in real time so as to reflect the torque applied to the stirring tool (3).
4. The apparatus for detecting a failure to break in a friction stir welding tool of claim 1, wherein: the detection module (6) reads the value of the pressure sensor (4) and the value of the torque sensor (5) in real time, a fracture detection judgment program is built in, and when the fracture detection judgment program is triggered, the fracture detection module (6) of the stirring tool (3) sends fracture alarm information of the stirring tool (3) by setting a corresponding pressure change threshold value and a corresponding torque change threshold value.
5. A method for detecting the fracture failure of a friction stir welding tool is characterized by comprising the following steps: the method comprises the following steps:
step one, determining the size of a corresponding static shaft shoulder (2) and a through hole on the static shaft shoulder according to the material and thickness parameters of a welding material (7), the length of a stirring tool (3) corresponding to the through hole and the diameter of the stirring tool (3);
step two, setting an acting force criterion F in the detection module (6) according to the static shaft shoulder (2), the stirring tool (3) and the rotating speed of the main shaft during welding, the welding feeding speed and the set value of the welding pressurethresholdCriterion T of sum torquethreshold；
Step three, when the set feeding speed is reached, the detection module (6) starts to work;
step four, the detection module (6) collects the acting force applied to the stirring tool (3) by the welding material (7) measured by the pressure sensor (4), then calculates the difference value of the previous sampling period and the next sampling period on the acting force, and divides the value of the previous sampling period after taking the absolute value to obtain the value delta F of the change rate of the value;
step five, the detection module (6) collects the numerical value of the torque of the spindle motor (501) measured by the torque sensor (5) of the spindle motor (501), then calculates the difference value of the previous sampling period and the next sampling period obtained by the measurement of the torque sensor (5), and divides the numerical value of the previous sampling period after taking the absolute value to obtain the numerical value Delta T of the change rate;
step six, comparing the calculated delta F and delta T with a set value,
when Δ F> FthresholdAnd Δ T> TthresholdWhen the temperature of the water is higher than the set temperature,
the detection module (6) judges that the stirring tool (3) is broken at the moment, and the breakage detection module (6) of the stirring tool (3) sends alarm warning information; when the delta F and the delta T do not accord with the criterion, the program continues to run and the parallel comparison calculation is carried out until the welding is finished.
6. The method of claim 5 for detecting a failure to break in a friction stir welding tool, wherein: the detection module (6) revises the acting force criterion F according to the delta F and the delta TthresholdCriterion T of sum torquethreshold(ii) a Criterion of acting force FthresholdCriterion T of sum torquethresholdThe specific values of (a) gradually approach (Δ F) and (Δ T).
7. The method of detecting a failure to fracture of a friction stir welding tool according to claim 5, wherein: when the detection module (6) judges that the stirring tool (3) is broken, a log file of 'breaking time-breaking event' is formed.
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Cited By (1)
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