Design and Construction of a Novel Friction Crushing Welding Machine

Sánchez-Femat, Oscar Francisco; Delgado-Pamanes, Miguel Fernando; Reyes-Osorio, Luis Arturo; Suárez-Rosales, Miguel Ángel; Chávez-Alcala, José Federico; Flores-Pinedo, Rafael; Becerra-Márquez, Josúe Daniel

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ARTÍCULOS CIENTÍFICOS • Soldag. insp. 26 • 2021 • https://doi.org/10.1590/0104-9224/SI26.06 copiar

Design and Construction of a Novel Friction Crushing Welding Machine

Autoria SCIMAGO INSTITUTIONS RANKINGS

Abstract:

Friction welding processes are used in diverse areas such as the naval, automotive, and aerospace sectors. These processes offer great flexibility and energy efficiency in the generation of joints. Friction crush welding is a solid-state joining process in which a rotating tool operates along a joint line between two parts generating frictional heat and mechanical agitation to form a joint. In this work, the design and construction of a friction crush welding machine is presented, the stages included: a) the welding disc design, b) calculus of sheets, c) selection of the motor-screw advancement and d) calculus of the support structure. In the evaluation of the equipment, weld joints of Zn-22% Al-2% Cu (zinalco) and Al A380 alloy were developed presenting weld beads with a continuous material flow.

Key-words:
Friction crush welding; analysis; design

Característica	Desarrollo	Valor (mm)
Diámetro del contorno del disco, $d_{c}$	$d_{c} = \sqrt{2} * (4 * 2,2 mm + 1 mm)$	$13,85$
Ancho del contorno del disco, $W_{C}$	$W_{C} = 2 * 4,4 + 1$	$9,8$
Longitud de contacto entre los materiales a soldar y el disco, $L_{P}$	$L_{P} = \sqrt{57,8 m m (2,88 m m)}$	$12,90$

Característica geométrica (mm)	Número de disco para soldadura
	Calculado	Simulados
	Calculado	D1	D2	D3	D4	D5
Radio de curvatura, $R_{C}$	6,925	7,93	19,30	20,00	22,00	10,00
Hombro, S	5,00	5,00	0,50	2,80	2,80	5,00
Radio del disco, $R_{D}$	60,00	60,00	60,00	40,00	40,00	40,00
Espesor, $W_{D}$	19,80	20,00	20,00	20,00	25,00	25,00

Característica	Desarrollo	Valor
Máximo valor de deformación, ϵ	$\in = l n (\frac{7,28 m m}{4,4 m m})$	$0,503$
Esfuerzo de cedencia promedio, ${\bar{Y}}_{F}$	$\bar{Y_{F}} = \frac{205 M P a * {0,504}^{0,20}}{1 + 0,20}$	$148,95 M P a$
Fuerza, $F$	$F = 148,95 M P a * 0,0054 m * 0,0129 m$	$10,375 k N$
Torque, $T$	$T = 0,5 * 10,375 k N * 0,0129 m$	$66,918 N m$
Potencia, $P$	$P = \frac{2 * π * 66,918 N m * 1.000 r p m}{60.000}$	$7,01 k W$

Característica	Valor (mm)
Diámetro, ø	20,00
Paso de rosca, P	2,00
Diámetro de rosca, ø_r	28,64
Diámetro de paso, ø_p	19,18
Diámetro de medio, ø_m	19,00

Característica	Desarrollo	Valor
Revoluciones por minutos, N	$N = \frac{60 (0,166 \frac{m}{s})}{0,002}$	$5000 r p m$
Potencia requerida, P	$P = \frac{2 * π * 2,723 N * m * 5.000 r p m}{60.000}$	$1,42 k W$

Característica	Desarrollo	Valor
Revoluciones por minutos, N	$N = \frac{60 (0,0166667 \frac{m}{s})}{0,002}$	$500 r p m$
Potencia requerida, P	$P = \frac{2 * π * 40 N * m * 500 r p m}{60.000}$	$2,09 k W$

Propiedad	Valor (N/m2)
Módulo de Young, E	2 x 1011
Esfuerzo Último de Tensión, S_ut	40,00 x106
Esfuerzo de Cedencia, S_y	250,00 x106

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