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摘 要
搅拌摩擦焊技术是90年代发展起来的、自发明到工业应用时间跨度最短和发展最快的一项新型固相连接新技术，公认为是最有前途和最适合航空材料以及结构件制造的工艺方法之一。搅拌摩擦焊（FSW）是一个相对较新的固态焊接过程。这种连接技术具有节能，高效，环保，用途广泛的特点。特别是，它可以用于高强度航天铝合金和其他金属的合金，这些合金是很难通过常规焊接熔焊。 FSW被认为是金属连接在十年的发展中最有标志性的成果。[6]
本文设计出的双搅拌轴摩擦焊焊机，总功率约3千瓦，适合于普通厚度的铝及其合金的工艺试验试件的焊接，搅拌摩擦头转速约6000r/min，焊接速度为500—600mm/min，最大加工焊缝厚度15mm，焊缝长度500mm。文中介绍了搅拌摩擦焊焊接技术的基本原理和特点，概要地介绍了搅拌摩擦焊的技术优势、研究现状、工业应用和发展前景。针对工艺试验试件搅拌摩擦焊机，主要设计、计算和校核了设备各主要部分，均能够满足试验用焊机的要求。
本机器由于采用双搅拌头，因此相对于一般的搅拌摩擦焊焊机效率更高。相对于一般的搅拌摩擦焊焊机，该机器也非常的经济和容易操作。
关键词：双搅拌轴摩擦焊；固相焊接；铝合金焊接；焊机设计
Abstract
Friction stir welding (FSW) was firstly used in the 1990s, which is swiftest in development and is shortest in time from being invented to being applied, it is also treated as one of the technology that have a bright future and the most suitable for aviation and component manufacture.Friction stir welding (FSW) is a relatively new solid-state joining process. This joining technique is energy efficient, environment friendly, and versatile. In particular, it can be used to join high-strength aerospace aluminum alloys and other metallic alloys that are hard to weld by conventional fusion welding. FSW is considered to be the most significant development in metal joining in a decade.
This task is to sign a machine used in laboratory. Its power is about three kilowatt, rotation rate approximately is 6000r/min, and welding speed is from 500 to 600mm/min. It can be apply to welding the aluminum and aluminum alloys. In addition, the welding thickness can’t exceed 15mm and length 500mm. In this paper, the basal principle and features of FSW is introduced, and the priority, prospect and application are also expounded. Importantly, main parts of the FSW machine was designed and calculated, the calculation results shows that the FSW machine designed in the paper can accord with the demand of the testing in laboratory.
The advantage of this machine is that it is more efficient than the normal FSW machine because it has a twin-stir.Compared with other machine,it is also very cheap and easy-to-use.
Key words：Twin-stir Friction welding；Solid phase welding；Aluminum alloys welding；Application prospect；Welding machine design
目 录
摘 要
Abstract
第1章 绪论 1
1.1搅拌摩擦焊简介 1
1.2国内外研究现状及发展趋势 2
1.2.1搅拌摩擦焊技术发展历史及研究成果 2
1.2.2 国内搅拌轴摩擦焊技术发展发展应用 3
1.2.3搅拌摩擦焊中双搅拌轴摩擦焊技术目前的应用情况和前景 5
1.3本次设计的内容和意义 6
第2章 双搅拌轴搅拌摩擦焊机设计 7
2.1 焊机的总体设计以及规划 7
2.2 各部件设计 8
2.2.1 搅拌头及夹具设计 8
2.2.2 搅拌系统功率计算 9
2.2.3搅拌系统传动齿轮设计 11
2.2.4搅拌轴的设计 15
2.2.5搅拌系统V带设计 20
2.2.6X-Y工作台设计 26
2.2.7传动丝杠设计 27
2.2.8减速齿轮的设计 30
2.2.9液压缸选择 33
第3章 AutoCAD与Pro/E软件简介 34
3.1软件简介 34
3.2三维模型 35
第4章 总结与展望 37
参考文献 38
致 谢 39
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