一种塑制汽车离合器泵的旋转摩擦焊接工艺参数的设计方法
|
摘要
针对一种塑制汽车离合器总泵的上下泵体在旋转摩擦焊接工艺中焊接参数难以确定的问题,提出了一种基于旋转摩擦焊接温度的焊接参数设计方法。通过二次正交回归试验设计,采用响应曲面法,建立了由主轴主轴转速、熔接压力和旋转圈数3个焊接参数在旋转焊接时摩擦面温度的预测模型;运用差示扫描量热法获得离合器泵体材料的熔点;在分析摩擦面温度与3个焊接工艺参数的二阶响应曲面图的基础上,结合摩擦面温度的预测模型,建立了焊接参数的关联耦合模型;依据该模型即可设计合理的焊接工艺参数。通过对焊接件焊接强度的评价,验证了焊接参数设计方法的合理性。离合器泵焊接量产的合格率达95%以上,证明了该焊接参数设计方法的可行性。
Aiming at the problems that the welding parameters of the upper and lower pump bodies of a plastic clutch general pump were difficult to be determined in the rotary friction welding processes, a welding parameter design method was proposed based on the rotating friction welding temperatures. Based on quadratic orthogonal regression design and response surface method, a prediction model of friction surface temperatures was established by three welding parameters of spindle speed, welding pressure and number of turns during rotating welding. The melting points of clutch pump materials were obtained by different scanning calorimetry. Based on the analysis of the friction surface temperatures and the two-order response surface diagram of three welding parameters, a coupling model of welding parameters was established based on the prediction model, and reasonable welding process parameters might be designed according to the model. Through the evaluation of welding strengths, the rationality of the design method of welding parameters was verified. With the aid of a numerical control welding system, the mass production of clutch pump welding was realized, which shows that the welding parameter design method is feasible.
Aiming at the problems that the welding parameters of the upper and lower pump bodies of a plastic clutch general pump were difficult to be determined in the rotary friction welding processes, a welding parameter design method was proposed based on the rotating friction welding temperatures. Based on quadratic orthogonal regression design and response surface method, a prediction model of friction surface temperatures was established by three welding parameters of spindle speed, welding pressure and number of turns during rotating welding. The melting points of clutch pump materials were obtained by different scanning calorimetry. Based on the analysis of the friction surface temperatures and the two-order response surface diagram of three welding parameters, a coupling model of welding parameters was established based on the prediction model, and reasonable welding process parameters might be designed according to the model. Through the evaluation of welding strengths, the rationality of the design method of welding parameters was verified. With the aid of a numerical control welding system, the mass production of clutch pump welding was realized, which shows that the welding parameter design method is feasible.
引文
[1] KALSI N S,SHARMA V S.A Statistical Analysis of Rotary Friction Welding of Steel with Varying Carbon in Workpieces[J].International Journal of Advanced Manufacturing Technology,2011,57(9/12):957-967.
[2] 贺建超,张田仓,何胜春.Ti600/TC17钛合金惯性摩擦焊接头组织与力学性能研究[J].机械工程学报,2017,53(22):95-100.HE Jianchao,ZHANG Tiancang,HE Shengchun.Research of Microstructure and Mechanical Properties of Ti600/TC17 Inertia Friction Welding Joints[J].Journal of Mechanical Engineering,2017,53(22):95-100.
[3] RAHMI M,ABBASI M.Friction Stir Vibration Welding Process:Modified Version of Friction Stir Welding Process[J].International Journal of Advanced Manufacturing Technology,2017,90(1/4):141-151.
[4] TAPPE P,POTENTE H.New Results on the Spin Welding of Plastics[J].Polymer Engineering & Science,1989,29(23):1655-1660.
[5] KENNEY W E.Joint Design a Critical Factor in Strong Bonds[J].Engineering Design,1985:1-3.
[6] CRAWFORD R J,TAM Y.Friction Welding of Plastics[J].Journal of Materials Science,1981,16(12):3275-3282.
[7] STOKES V K.Analysis of the Friction (Spin)Welding Process for Thermoplastics[J].Journal of Materials Science,1988,23(8):2772-2785.
[8] STOKES V K,POSLINSKI A J.Effects of Variable Viscosity on the Steady Melting of Thermoplastics during Spin Welding[J].Polymer Engineering & Science,1995,35(5):441-459.
[9] 邓朝晖,符亚辉,万林林,等.面向绿色高效制造的铣削工艺参数多目标优化[J].中国机械工程,2017,28(19):2365-2372.DENG Zhaohui,FU Yahui,WAN Linlin,et al.Multi Objective Optimization of Milling Process Parameters for Green High-performance Manufacturing[J].China Mechanical Engineering,2017,28(19):2365-2372.
[10] 杜俊,赵国敏,潘明珠,等.聚乙二醇对纤维素纳米晶体/聚羟基丁酸戊酸酯复合材料性能的影响[J].复合材料学报,2017,34(4):714-722.DU Jun,ZHAO Guomin,PAN Mingzhu,et al.Effects of Polyethylene Glycol on the Properties of Cellulose Nanocrystals/PHBV Composites[J].Acta Materiae Compositae Sinica,2017,34(4):714-722.
[2] 贺建超,张田仓,何胜春.Ti600/TC17钛合金惯性摩擦焊接头组织与力学性能研究[J].机械工程学报,2017,53(22):95-100.HE Jianchao,ZHANG Tiancang,HE Shengchun.Research of Microstructure and Mechanical Properties of Ti600/TC17 Inertia Friction Welding Joints[J].Journal of Mechanical Engineering,2017,53(22):95-100.
[3] RAHMI M,ABBASI M.Friction Stir Vibration Welding Process:Modified Version of Friction Stir Welding Process[J].International Journal of Advanced Manufacturing Technology,2017,90(1/4):141-151.
[4] TAPPE P,POTENTE H.New Results on the Spin Welding of Plastics[J].Polymer Engineering & Science,1989,29(23):1655-1660.
[5] KENNEY W E.Joint Design a Critical Factor in Strong Bonds[J].Engineering Design,1985:1-3.
[6] CRAWFORD R J,TAM Y.Friction Welding of Plastics[J].Journal of Materials Science,1981,16(12):3275-3282.
[7] STOKES V K.Analysis of the Friction (Spin)Welding Process for Thermoplastics[J].Journal of Materials Science,1988,23(8):2772-2785.
[8] STOKES V K,POSLINSKI A J.Effects of Variable Viscosity on the Steady Melting of Thermoplastics during Spin Welding[J].Polymer Engineering & Science,1995,35(5):441-459.
[9] 邓朝晖,符亚辉,万林林,等.面向绿色高效制造的铣削工艺参数多目标优化[J].中国机械工程,2017,28(19):2365-2372.DENG Zhaohui,FU Yahui,WAN Linlin,et al.Multi Objective Optimization of Milling Process Parameters for Green High-performance Manufacturing[J].China Mechanical Engineering,2017,28(19):2365-2372.
[10] 杜俊,赵国敏,潘明珠,等.聚乙二醇对纤维素纳米晶体/聚羟基丁酸戊酸酯复合材料性能的影响[J].复合材料学报,2017,34(4):714-722.DU Jun,ZHAO Guomin,PAN Mingzhu,et al.Effects of Polyethylene Glycol on the Properties of Cellulose Nanocrystals/PHBV Composites[J].Acta Materiae Compositae Sinica,2017,34(4):714-722.