| In order to overcome the existing stud welding equipment’s disadvantage, we tend to develop a brand new friction weld machine system, which can flexibly friction weld stud to plate in all position. So we try to imitate the working condition of the robot friction welding system to weld 6061 aluminium alloy. And the experiment result testified that it’s quite possible to carry out friction welding in this new welding system.In the process of development and designing of the friction welding system, the works we do as follows:1. Conducting finite element analysisFirstly, conducting finite element static analysis of the bearing frame to check whether it is capable of carrying loads in kinds of working condition. Secondly, carrying on its structural optimization design to make it meet the requirements for strength and stiffness of the welding machine, trying to reduce weight of welding head. Finally though the finite element modal analysis of bearing frame, calculated that resonance behavior of welding head does not occur when motor’s rotation speed below 3000r/min.2. Designing the friction stud welding headThough the computer-aided design software UG to design the bearing frame, spindle motor, automatic clamp mechanism, heating coil movement mechanism, protection gas device.3. Study on the automatic control systemIn order to realize automatic welding of robot friction stud welding system, electrical and hydraulic control system designing is necessary. In this chapter we just do preliminary exploration on the control system, hoping to be helpful to follow-up automation system designing work.4. Compositing heating friction stud welding probe testCarrying out welding experiment without heating and with heating to find out the range of stud welding in the robot, to compare the effect of friction stud welding in the two different working situation, and confirm whether the compositing heat friction welding process can reduce the upsetting force.This project has clear positioning and targets at the industrial application, involving a wide range of knowledge in the process of research and development, the research of general theory parallel with development of engineering application, and all the research and development is to make product meet the requirements of industrial application. |
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