The Design Of Dual-function System Of Friction Stud Welding And Friction Stir Welding

Based on the character of solid phase connecting,the friction welding was widely used in industry.As for the friction stud welding and the friction stir welding,the corresponding equipments are heavier and lack of agility.In order to increase the automation in friction welding and reduce the cost in equipments,based on the common ground of these two welding,we tended to get the friction stud welding and the friction stir welding together into a welding system by a large load robot and some other peripheral equipments.Before doing the work about the welding system integration,we did some process experiments of the friction stud welding and the friction stir welding in order to provide parameter-basis for the follow-up work,and the 6061 aluminum alloy was chosen as the experimental material.As for the friction stud welding,we studied the influence to welding quality of friction press,stud rotation rate,heating temperature and welding structure.As for the friction stir welding,we studied the influence to welding quality of stir-welding head rotation rate and welding speed.According to the size of the connecting flange at the end of main shaft 6 of the robot,we designed the key part,a connection for connecting the electromotor system and robot,then analysied the ultimate stress condition of the connection during the work?Based on the above analysis,we did finite element analysis and checkout by 3D drawing soft SolidWorks to ensure the reliability and security.We designed the control system of the equipment,and the control system mainly included the control procedure of every part's cooperative work.The dual-function friction welding system mainly included the robot?KR C4 control cabinet?transducer?frequency motor and hydraulic pressure station.Taking advantages of the openness of the KUKA robot's control system,we controlled these peripheral equipments by the IO module in KR C4 control cabinet.According to the technological process of welding,we designed the control programs,and used the welding system to try the friction stud welding and the friction stir welding in order to check the property of the welding system.As for the shortcomings in designs,we gave some solutions so it will be more convenient for the improvement and upgrade of the dual-function friction welding system.