Electric simulation inertia friction welding technology
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摘要: 为适应摩擦焊接设备的发展，降低制造成本，在对惯性摩擦焊接过程运动学方程分析基础上，结合电模拟惯量技术，开发出了电模拟惯性摩擦焊接技术及设备. 结果表明，电模拟惯性摩擦焊接过程中各参数随时间的变化规律，以及惯量大小对焊接参数的影响规律，符合惯性摩擦焊接的一般规律. 相同惯量下，电模拟惯性摩擦焊接与机械惯量惯性摩擦焊接过程转速曲线变化趋势一致. 采用电模拟惯性摩擦焊接技术，所需惯量可以设定成大于系统基本惯量，也可以设定成等于或低于系统基本惯量，还可以补偿主轴机械摩擦阻力对焊接过程参数的影响.Abstract: In order to adapt to the current development of friction welding equipment and reduce the manufacturing cost, the electro-simulated inertia friction welding technology and equipment are developed, based on the analysis of the kinematics equation of inertia friction welding process and the electric simulation inertia technology. The result shows that the regularity of the change of parameters over time and the influence of inertia size on welding parameters are in accordance with the general law of inertia friction welding during the electric simulation. The rotational speed curve of inertial friction welding is consistent with that of mechanical inertia friction welding process under the same inertia. The inertia can be set to be larger than the basic inertia of the system, and can be set to equal or lower than the basic inertia of the system by electric simulation inertial friction welding technology. The effect of friction resistance of spindle on the parameters of welding process can be compensated by electro-simulated inertial friction welding technique.
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图 3 电模拟惯性摩擦焊接过程各参数变化曲线
Figure 3. Parameters change curve of the friction welding experiments
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图 4 模拟不同惯量下焊接转速曲线对比
Figure 4. Speed curve contrast of the welding experiments under simulate different inertia
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图 5 电惯量与机械惯量惯性摩擦焊接过程转速曲线对比
Figure 5. Speed curves of inertia weldings with the mechanical inertia and electronic inertia
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图 6 主轴机械摩擦阻力矩对焊接过程各参数变化曲线的影响
Figure 6. Parameters change curve of friction welding experiments
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图 7 连续驱动摩擦焊与惯性摩擦焊接接头形貌
Figure 7. Morphology of inertia friction welded and continuous drive friction welded join
表 1 不同惯量下焊接试验参数与结果
Table 1 Parameters and results of different inertia experiments
惯量J/(kg·m2) 初始转速n/(r·min−1) 摩擦压力pf/MPa 摩擦缩短量S/mm 焊接时间t/s 5 1 600 70 2.9 2.6 6.36 1 600 70 3.0 3.3 8 1 600 70 4.9 3.9 11 1 600 70 7.9 5.3 
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表 2 电惯量与机械惯量惯性摩擦焊接对比试验参数与结果
Table 2 Parameters and result of the contrast experiment of the mechanical and electronic inertia friction welding
惯量方式 初始转速
n/(r·min−1)摩擦压力pf/MPa 摩擦缩短量S/mm 焊接时间
t/s机械惯量 1 000 70 2.1 1.6 电模拟 1 000 70 2.1 1.6
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表 3 参数设定与结果
Table 3 Parameters setting and result
惯量J/(kg·m2) 初始转速n/(r·min−1) 是否补偿
阻力矩摩擦缩短量S/mm 焊接时间t/s 6.36 1 600 否 7.51 5 6.36 1 600 是 12.29 7.79
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