双机镜像搅拌摩擦焊顶锻力变化规律与影响因素研究

Research on Variation Law and Influencing Factors of Forging Force in Dual-Robot Mirror Friction Stir Welding

随着搅拌摩擦焊板厚增大,设备承载能力无法满足单侧搅拌摩擦焊的高顶锻力要求,因而难以形成质量良好的焊缝。为了降低设备所受顶锻力,本文提出了一种双机镜像搅拌摩擦焊工艺方法,研究了工艺过程中顶锻力的变化规律和影响因素,并验证了该工艺的可行性和优越性。首先,建立热力耦合的有限元仿真模型,得到顶锻力随板厚的变化规律,同时得到了双机镜像搅拌摩擦焊工艺能够减小顶锻力的结论;之后,建立顶锻力估计模型,并基于数据驱动对模型进行试验修正和验证,实现无传感器的顶锻力监测;最后,在搭建好的试验平台样机上开展了镜像焊接试验、3组工艺参数的多因素试验及单侧搅拌摩擦焊对比试验,得到顶锻力随时间的变化规律和工艺参数的影响,验证了双机镜像搅拌摩擦焊工艺可以减小搅拌头所受顶锻力、降低设备承载能力需求的作用。

As the thickness of the friction stir welding plate increases,the bearing capacity of the equipment cannot meet the requirement of high forging force of unilateral friction stir welding,so it is difficult to form a good quality weld.To reduce the forging force on the equipment,a dual-robot mirror friction stir welding process is proposed in this paper.The variation and influencing factors of the forging force are studied,and the feasibility and superiority of the process are verified.Firstly,a thermodynamic couplingfinite element simulation model is established to obtain the variation law of the forging force with plate thickness,and the conclusion that the dual-robot mirror friction stir welding process can reduce the forging force is obtained.After that,the forging force estimation model is established,and the experimental correction and verification of the model based on data-driven is carried out to realize sensorless forging force monitoring.Finally,the mirror welding experiment,three-group process parameter multi-factor experiment,and unilateral friction stir welding comparison experiment are carried out on the prototype platform.The variation of the forging force with time and process parameters is obtained,and it is proved that the dual-robot mirror friction stir welding process can reduce the forging force on the stirring head and the bearing capacity requirement of the equipment.