Abstract
The friction stir welding robot for aerospace applications developed by the research group is subject to the effects of size, working conditions, and other conditions during the operation. The load conditions of the friction stir welding robot are harsh, and the strength and stiffness tests of the whole machine need to be carried out. Five typical working conditions of the friction stir welding robot are analyzed. By analyzing the system composition and configuration of the robot, the loading conditions of the robot stirring head during the welding process are accurately simulated, and this is used as the stiffness and strength check. The boundary conditions of the robot are simulated and analyzed under typical working conditions. The results show that the data of each part of the robot under load are obtained for a given size of the rocket cap welding. After analysis, the maximum normal displacement of the friction stir welding robot reached 0.6424 mm and the maximum stress was 79.21 MPa under the condition of melon flap welding.
Highlights
At present, in the fields of China’s aerospace, military, and national defense, many large thin-walled parts have to be welded in sections due to their large size and complex structure, such as fuel tanks for heavy-duty rocket (CZ-5) engines, the skin structure of large aircraft (C919), and the intake duct of the new generation fighter (J-10)
This article introduces in detail an Friction stir welding (FSW) robot specially developed by the research group in the aerospace field, including system structure composition, degree of freedom configuration, compensation principle, spindle system design, and five typical working conditions
The results show that the newly developed FSW robot is capable of welding large and complex space curved surfaces, and its own process performance is good, which provides a practical solution for achieving high-precision welding in the aerospace field
Summary
In the fields of China’s aerospace, military, and national defense, many large thin-walled parts have to be welded in sections (shards) due to their large size and complex structure, such as fuel tanks for heavy-duty rocket (CZ-5) engines, the skin structure of large aircraft (C919), and the intake duct of the new generation fighter (J-10). This article introduces in detail an FSW robot specially developed by the research group in the aerospace field, including system structure composition, degree of freedom configuration, compensation principle, spindle system design, and five typical working conditions. The results show that the newly developed FSW robot is capable of welding large and complex space curved surfaces, and its own process performance is good, which provides a practical solution for achieving high-precision welding in the aerospace field. The transmission mechanism mainly adopts ball screw transmission, including the screw nut pair and the support and drive structure at both ends. The center of mass compensation mechanism is mainly used to compensate for the eccentricity problem when the Z-axis ram is extended, so that the end of the tool of the stirring head and the workpiece to be welded always maintain a certain position.
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