Friction welding method and machine tool

Disclosed is a friction welding method including: a heating step wherein, in relation to joining surfaces (S1, S2) defined by opposite end surfaces of a pair of materials (W1, W2), the pair of materials (W1, W2) are moved from a state in which their axes are unaligned with each other, in a direction for aligning the respective axes with each other, to a prescribed position where the joining surfaces (S1, S2) are brought into contact with each other and friction heated; and a pressure contacting step wherein the pair of materials are brought into pressure contact with each other. The method is characterized in that the heating step and the pressure contacting step are carried out while rotating each of the materials (W1, W2) at the same rotation speed in the same direction, as seen from one side in the axial direction.

TECHNICAL FIELD

This disclosure relates to a friction welding method and a machine tool.

BACKGROUND

In the state of the art, there is known a method for friction welding a pair of materials using a machine tool, such as a lathe including a pair of spindles arranged opposite to each other. In this method, a pair of materials held by the pair of spindles are rotated in mutually opposite directions as seen from one side in the axial direction, and moved from a state where their axes are displaced until they are aligned and their joining surfaces are brought into contact with each other for friction heating and, the pair of materials after alignment of their axes are brought into pressure contact with each other (refer, for example, to JPH 6-312279 A1 (PTL 1)).

CITATION LIST

Patent Literature

SUMMARY

Technical Problem

In the conventional friction welding method as disclosed in PTL 1, friction heating is carried out by rotating the pair of materials in mutually opposite directions as seen from one side in the axial direction. It is therefore necessary to carry out the pressure contacting after stopping the rotation of each material, and it may not be easy to maintain each material in a state allowing the friction welding to be carried out, in the step of stopping each spindle for stopping the rotation of each material.

In view of the problems noted above, it would be helpful to provide a friction welding method and a machine tool, whereby the friction welding of the materials can be carried out while rotating each material.

Solution to Problem

According to the present disclosure, there is provided a friction welding method, comprising: a heating step wherein, in relation to joining surfaces defined by opposite end surfaces of a pair of materials that are held by a respective pair of opposite spindles, the pair of materials are moved from a state in which their axes are unaligned with each other, in a direction for aligning the respective axes with each other, to a prescribed position where the joining surfaces are brought into contact with each other and friction heated, and a pressure contacting step wherein the pair of materials are brought into pressure contact with each other at the prescribed position, characterized in that the heating step and the pressure contacting step are carried out while rotating each of the materials at the same rotation speed in the same direction, as seen from one side in the axial direction.

In the friction welding method according to the present disclosure, with the configuration as described above, it is preferred that the pressure contacting step is carried out at a position where the axes of the pair of the materials are aligned with each other.

It is preferred that the friction welding method according to the present disclosure, with the configuration as described above, further comprises a cutting step carried out after the pressure joining step, for cutting the materials while being rotated at the same rotation speed and in the same direction as in the heating step and the pressure contacting step, as seen from one side in the axial direction.

According to the present disclosure, there is further provided a machine tool comprising a pair of spindles arranged opposite to each other, and a control unit for controlling the movement and rotation of the spindles and carrying out a heating step wherein, in relation to joining surfaces defined by opposite end surfaces of a pair of materials that are held by a respective pair of opposite spindles, the pair of materials are moved from a state in which their axes are unaligned with each other, in a direction for aligning the respective axes with each other, to a prescribed position where the joining surfaces are brought into contact with each other and friction heated; and a pressure contacting step wherein the pair of materials are brought into pressure contact with each other at the prescribed position, characterized in that, under the control by means of the control unit, the heating step and the pressure contacting step are carried out while rotating the spindles at the same rotation speed in the same direction, as seen from one side in the axial direction.

In the machine tool according to the present disclosure, with the configuration as described above, it is preferred that, under the control by means of the control unit, the pressure contacting step is carried out at a position where the axes of the pair of materials are aligned with each other.

The machine tool according to the present disclosure, with the configuration as described above, may further comprise a tool, of which the movement is controlled by the control unit, wherein, under the control by means of the control unit, a cutting step is carried out after the pressure joining step, for cutting the materials by the tool while the spindles are rotated at the same rotation speed and in the same direction as in the heating step and the pressure contacting step, as seen from one side in the axial direction.

Advantageous Effect

The present disclosure thus provides a friction welding method and a machine tool adapted to carry out the heating step and the pressure contacting step while rotating each material, and easily maintain each material in a state where friction welding can be performed.

DETAILED DESCRIPTION

The machine tool1illustrated inFIG. 1has a pair of spindles arranged on a base2, i.e., a first spindle3aand a second spindle3b. The first spindle3ais rotatably supported by a first headstock4a, and the second spindle3bis rotatably supported by a second headstock4b. The first spindle3aand the second spindle3bare arranged opposite to each other at a predetermined interval.

The first spindle3aincludes a first chuck5aat the tip so that a first workpiece W1can be gripped by the first chuck5a. Similarly, the second spindle3bincludes a second chuck5bat the tip so that a second workpiece W2can be gripped by the second chuck5b.

The first spindle3ais driven for rotation by a first drive source6a, and the second spindle3bis rotationally driven by a second drive source6b. As the first drive source6aand the second drive source6b, for example, there may be used an electric motor. By rotating the first spindle3awith the first drive source6a, the first workpiece W1held by the first spindle3acan be rotated. Similarly, by rotating the second spindle3bwith the second drive source6b, the second workpiece W2held by the second spindle3bcan be rotated.

The first headstock4ais mounted on the base2via a first Z-axis guide rail9aextending in the axial direction (Z-axis direction) of the first spindle3a, a first saddle10aslidably mounted on the first Z-axis guide rail9a, and a first saddle10aand a first X-axis guide rail11asupported by the saddle10ato extend in a horizontal direction (X-axis direction) perpendicular to the axial direction of the first spindle3a. The first spindle3ais driven for movement in the Z-axis direction and the X-axis direction together with the first headstock4a, via ball screws or the like arranged between the first saddle10aand the base2and also between the first saddle10aand the first headstock4a, by means of a motor or the like for rotating the ball screws.

The second headstock4bis mounted on the base2via a second Z-axis guide rail9bextending in the axial direction (Z-axis direction) of the second spindle3b, a second saddle10bslidably mounted on the second Z-axis guide rail9b, and a second X-axis guide rail11bsupported by the saddle10bto extend in a horizontal direction (X-axis direction) perpendicular to the axial direction of the second spindle3b. The second spindle3bis driven for movement in the Z-axis direction and the X-axis direction together with the second headstock4b, via ball screws arranged between the second saddle10band the base2and also between the second saddle10band the second headstock4b, by means of a motor or the like for rotating the ball screws.

In the embodiment illustrated herein, both the first spindle3aand the second spindle3bare driven for movement in the Z-axis direction and the X-axis direction. However, for example, only one of the first spindle3aand the second spindle3bmay be configured to be driven for movement in the Z-axis direction and the X-axis direction. It is sufficient for the first spindle3aand the second spindle3bto be relatively movable in the Z-axis direction and the X-axis direction.

The machine tool1includes a cutting tool7. The cutting tool7is mounted on the moving means8and is configured to be movable by moving means8. The first workpiece W1and the second workpiece W2is subjected to cutting step by urging the blade portion7aof the cutting tool7against the first workpiece W1and the second workpiece W2in a state where the first workpiece W1and the second workpiece W2are rotated together with the first spindle3aand the second spindle3bat a predetermined rotation speed (revolution speed) corresponding to the cutting step. The cutting tool7may be separately provided for the processing of the first workpiece W1on the first spindle3a, and for the processing of the second workpiece W2on the second spindle3b.

In case where both the first spindle3aand the second spindle3bare configured to be driven for movement in the Z-axis direction and the X-axis direction, instead of providing the moving means8, the cutting tool7may be fixedly mounted on the tool rest such that, by relatively moving the spindle3aand the second spindle3bwith respect to the cutting tool7, the blade7aof the cutting tool7is pressed against the joining workpiece W3for carrying out the cutting step.

The machine tool1includes a control unit C. The control unit C may be comprised of a microcomputer including a CPU (central processing unit) and storage means, such as a memory. The control unit C is connected to the first drive source6a, the second drive source6b, the moving means8, the Z-axis and X-axis slide moving mechanisms for the two headstocks4a,4b, and the like, and may serve to integrally control such operations as the rotation of the two spindles3a,3b. the movement of the cutting tool7, and the movement of the two headstocks4aand4b. The machine tool1may be comprised of a lathe, such as a CNC lathe, for example.

The first workpiece W1and the second workpiece W2may, for example, be comprised of metal bars or the like with circular cross-section and end faces facing in the axial direction, i.e., the first joining surface S1and the second joining surface S2each having a flat surface perpendicular to the axial direction. The first workpiece W1may be an elongate round bar inserted from the rear end of the first spindle3a, and the second workpiece W2may be the portion of the first workpiece W1that has been cut and processed on the first spindle3aand remaining as the residual material.

In the state illustrated inFIG. 1in which the first workpiece W1is gripped by the first spindle3aand the second workpiece W2is gripped by the second spindle3b, as illustrated inFIG. 1, when the first spindle3aand the second spindle3bare relatively moved along the Z axis and the X axis, the first workpiece W1and the second workpiece W2are moved such that the Z-axis direction positions of the first joining surface S1and the second joining surface S2coincide with each other and the first joint surface S1and the second joint surface S2are arranged such that their axes are unaligned in the X-axis direction and separated from each other in the X-axis direction.

Due to the operation of the first spindle3aand the second spindle3b, in the state in which the first workpiece W1and the second workpiece W2are rotated at the same rotation speed in the same direction as seen from one side in the axial direction, the first workpiece W1is moved from the state illustrated inFIG. 2A, in the X-axis direction relative to the second workpiece W2, such that the first joint surface S1and the second joint surface S2rotating at the same rotation speed and in the same direction are brought into contact with each other to carry out friction heating (heating step). The heating step is continued until the first workpiece W1and the second workpiece W2are moved from the state in which the axes are unaligned as illustrated inFIG. 2B, to the state in which the axes are aligned as illustrated inFIG. 2C. Upon movement of the first workpiece W1in the X-axis direction relative to the second workpiece W2, the first workpiece W1and the second workpiece W2can be brought into contact with each other while being pressed against each other as necessary.

In the heating step, as noted above, the first workpiece W1and the second workpiece W2are rotating at the same rotation speed in the same direction as seen from one side in the axial direction. Thus, when the spindles are relatively moved from the state in which the surface S1and the second bonding surface S2are separated from each other in the X-axis direction, as illustrated inFIG. 3A, and the first joining surface S1and the second joining surface S2begin to contact with each other at an outer peripheral edge portion, as illustrated inFIG. 3B, the relative speed difference becomes the maximum and the largest friction heat is generated due to the rotation speed difference, thereby heating the materials with a large temperature rise. The friction heating is continued while maintaining the temperature of the joining surfaces at a level suitable for the joining, until a state is reached where the axes are aligned as illustrated inFIG. 3D.

In the heating step, as illustrated inFIG. 3C, the center portion of the first joining surface S1contacts with the outer peripheral edge portion of the second joining surface S2with a rotation speed difference, and the center portion of the second joining surface S2contacts with the outer peripheral edge portion of the first joining surface S1with a rotation speed difference. Thus, the central portion of the first joining surface S1and the central portion of the second joining surface S2are also heated by friction heat.

When the axes of the first spindle3aand the second spindle3bare aligned with each other, as illustrated inFIG. 3D, the relative rotation speed difference between the first spindle3aand the second spindle3bin their rotating state becomes zero (0), and the first spindle3aand the second spindle3bdo not rotate relative to each other, to terminate the heating step.

When the axes of the first workpiece W1and the second workpiece W2coincide with each other and the heating step is completed, a subsequent pressure joining step of pressing the first workpiece W1and the second workpiece W2is carried out. As illustrated inFIG. 4, the pressure joining step is carried out by moving the first workpiece W1and the second workpiece W2toward each other in the Z-axis direction, in a state where the axes of the workpieces are aligned and the workpieces are rotated at the same rotation speed in the same direction to stop the relative rotation, and pressing the first joint surface S1and the second joint surface S2in the axial direction (Z-axis direction) under a predetermined pressure (upset pressure).

With the pressure joining step after the heating step, the first workpiece W1and the second workpiece W2, as a pair of materials, are joined by friction welding. By the machine tool1, the first workpiece W1and the second workpiece W2are friction welded to each other, thereby forming a joined workpiece W3. In the present embodiment, the pressure joining step is carried out by moving the first spindle3aand the second spindle3btoward each other, based on a moving command to the first spindle3aand the second spindle3bfor moving the first workpiece W1and the second workpiece W2in the directions for urging them against each other.

Since the first spindle3aand the second spindle3bare moved in directions toward each other, as compared to the case wherein, with one spindle stopped in the Z-axis direction, the other spindle is moved in the Z-axis direction for urging the first workpiece W1and the second workpiece W2against each other, for example, it is possible readily to avoid errors of the control unit C based, for example, on the difference between the positions of the first spindle3aand the second spindle3b, and the positions of the movement command.

In the friction welding method according to the present embodiment, as described above, since the outer peripheral edge portion of the second joining surface S2contacts the center portion of the first joining surface S1, and the first portion contacts the central portion of the second joining surface S2in the heating step, as compared to the case wherein the first workpiece W1and the second workpiece W2are relatively rotated while being maintained in a coaxial state and thereby friction-heated, the central portion of the first joining surface S1and the central portion of the second joining surface S2are sufficiently friction-heated. Therefore, in the pressure contacting step, the temperature of the first joining surface S1and the second joining surface S2is entirely raised by friction, and the area of the joining surface by friction welding is increased, such that the first workpiece W1and the second workpiece W2can be subjected to friction-welding with improved joining strength.

As described above, in the friction welding method according to the present embodiment, the first workpiece W1and the second workpiece W2are rotated in the same direction at the same rotation speed to perform the heating step. As such, when the heating step is completed with the axes of the first workpiece W1and the second workpiece W2aligned with each other, the first joining surface S1and the second joining surface S2are relatively stopped. Thus, as illustrated inFIG. 6, after the heating step is completed, it is possible to continuously carry out the above-mentioned pressure joining step without stopping the rotation of the first workpiece W1and the second workpiece W2, by rotating the first workpiece W1and the second workpiece W2in the same rotation as the heating step without stopping the rotation of the first workpiece W1and the second workpiece W2.

The movement of the first spindle3aand the second spindle3bin the X-axis direction for relatively moving the first workpiece W1in the X-axis direction with respect to the second workpiece W2is carried out in consideration of the lowering of the temperature due to the decrease in the relative rotation speed difference such that, when the heating step is completed, the temperatures of the first joining surface S1and the second joining surfaces S2are maintained as a level required for the friction welding. By controlling the movement of the first spindle3aand the second spindle3b, such as the moving speed in the X-axis direction, the friction heating can be continuously and easily carried out while maintaining the temperature at a level suitable for the joining of the first joining surface S1and the second bonding surface S2, until the axes of the first workpiece W1and the second workpiece W2are aligned with each other.

Further, as illustrated inFIG. 7, the heating step is carried out by changing the position X of the first workpiece W1with respect to the second workpiece W2in the X-axis direction, and is completed when the axes of the first workpiece W1and the second workpiece W2are aligned and the position X becomes zero. When the first workpiece W1and the second workpiece W2are joined concentrically, after the heating step is completed, the pressure joining step may be carried out without changing the position X of the first workpiece W1in the X-axis direction with respect to the second workpiece W2. Therefore, it is possible to shorten the time from the heating step to the starting of the friction welding step, thereby allowing the friction welding to be carried out quickly.

In the friction welding method according to the present embodiment, the cutting step may be carried out continuously after the pressure joining step, while rotating the material as the workpiece W3, in the same direction as in the heating step and the welding step, and at the same rotation speed as seen from one side in the axial direction.

Preferably, the rotation speeds of the first workpiece W1and the second workpiece W2in the heating step and the press contacting step are set to a value suitable for allowing appropriate friction heating and carrying out the cutting operation by means of the cutting tool7.

At the joined portion of the workpiece W3in its outer peripheral surface, as illustrated inFIG. 4, a portion softened by the friction heat of the first workpiece W1and the second workpiece W2may be pushed radially outward at the time of pressure contacting, thereby forming burrs B. In the cutting step described above, as illustrated inFIG. 5, the moving means8may be operated to move the blade portion7aof the cutting tool7in the Z-axis direction, thereby carrying out the cutting step for removing the burrs B.

In the friction welding method according to the present embodiment, as seen from one side in the axial direction, the rotation direction and the rotation speed of the joining workpiece W3in the cutting step are set to be same as the rotation direction and the rotation speed of the first workpiece W1and the second workpiece W2in the heating step and the pressure joining step. Thus, after completion of the pressure joining step, it is possible to continuously carry out the cutting step while maintaining the rotation of the first workpiece W1and the second workpiece W2in the same direction and the same rotation speed as in the heating step and the pressure joining step, without adjusting the rotation speeds of the first workpiece W1and the second workpiece W2. In other words, as illustrated inFIG. 6, all of the heating step, the pressure joining step and the cutting step can be carried out while maintaining the same direction and the same rotation speed of the first workpiece W1and the second workpiece W2, without stopping the rotation of the first spindle3aand the second spindle3b. Therefore, after the first workpiece W1and the second workpiece W2are friction welded to each other, it is possible to promptly shift to the cutting step of the joined workpiece W3, thereby shortening the processing time.

As illustrated inFIG. 7, after completion of the friction welding, the cutting step can be continuously carried out without changing the position X of the first workpiece W1with respect to the second workpiece W2in the X-axis direction, Further, when it is unnecessary to release the first chuck5aand the second chuck5bbetween the pressure joining step and the cutting step, the processing time can be shortened from this aspect as well. It is necessary to release the first chuck5aand the second chuck5bwhen, after the removal of burrs B of the joined workpiece W3by means of the cutting step, the joined workpiece W3is gripped again by the first spindle3afor the cutting step.

FIGS. 8A and 8Bare explanatory views illustrating the procedure of a modification of the heating step, andFIGS. 9A to 9Cillustrate the positional relationship and rotation direction of the pair of materials as seen from one side in the axial direction in the heating step of the modification. InFIGS. 8A to 8B and 9A to 9C, members corresponding to those described above are denoted by the same reference numerals.

In the embodiment described above, as illustrated inFIG. 2A, the first workpiece W1and the second workpiece W2are arranged such that the first joining surface S1and the second joining surface S2are situated at the Z-axis position, with the respective axes unaligned with each other in the X-axis direction, thereby separating the first workpiece W1from the second workpiece W2in the X-axis direction, and the heating step is then started by relatively moving the first joint surface S1and the second joint surface S2into contact with each other in the X-axis direction.

In contrast, as illustrated inFIG. 8A, the first workpiece W1and the second workpiece W2are arranged such that the first joining surface S1and the second joining surface S2are arranged opposite to each other only at a part of the outer peripheral edge side, and spaced apart in the Z-axis direction with their axes shifted from each other in the X-axis direction, and the first workpiece W1and the second workpiece W2are then relatively moved in the Z-axis direction toward each other. By this, as illustrated inFIG. 8B, the outer peripheral side portion of the first joining surface S1and the outer peripheral side portion of the second joining surface S2can be brought into contact with each other, for starting the heating step. In this case, the first joining surface S1and the second joining surface S2can be reliably brought into contact under a predetermined pressing force with a simple control.

In the above-described modified example also, the first joining surface S1and the second joining surface S2start to contact each other at the outer peripheral portion, as illustrated inFIG. 9A, the central portion of the first joining surface S1and the central portion of the second joining surface S2are heated by friction heat, as illustrated inFIG. 9B, and the friction heating is continuously carried out while maintaining the surface temperature suitable for carrying out joining until the axes are aligned, as illustrated inFIG. 9C.

The present disclosure is not limited to the above-described embodiments, and various modifications may be made without departing from the scope thereof.

For example, the friction welding method according to the present embodiment is not limited to use of the machine tool1illustrated inFIG. 1, and may make use of another machine tool or the like, as long as a pair of arranged opposite to the spindles is included. In addition, the second workpiece W2may be gripped and friction welded by a spindle distinct from the second spindle3band provided to face the first spindle3a. In this case, it is preferred that the spindle for griping the second workpiece W2distinct from the second main spindle3bis provided on the second headstock4btogether with the second spindle3b. The second spindle3bmay be used for cutting, separately from the friction welding. The cutting step carried out separately from the friction welding on the second spindle3bmay be replaced by a cutting step carried out simultaneously with the friction welding by using a spindle distinct from the second spindle3b.

In the embodiment described above, for the purpose of bringing the first joint surface S1and the second joint surface S2into contact with each other in the outer peripheral edge portion, and aligning the axes with each other, an example has been presented wherein the first spindle3ais moved. Alternatively, the second spindle3bmay be moved, or both spindles may be relatively moved.

In the embodiment described above, an example has been presented wherein the axis of movement of the machine tool from a position in which the first joint surface S1and the second joint surface S2are brought into contact with each other at the outer peripheral edge portion, to a position in which the axes are aligned with each other, is the X axis. However, if the machine tool can be driven to move in the Y-axis direction, the friction welding method according to the present disclosure may also be carried out by moving the machine tool in the Y-axis direction.

In addition to maintaining the moving speed of the X-axis constant from a position in which the first joining surface S1and the second joining surface S2are brought into contact with each other at the outer peripheral edge portion, to a position in which the axes are aligned with each other, it is also possible to control the moving speed when aligning the axes, such that the moving speed is increased sequentially or stepwise toward the axis, as compared to the outer peripheral edge portion. By controlling the moving speed in the heating step, it is possible to precisely control the temperature of the joining surfaces.

In the embodiment described above, the first workpiece W1and the second workpiece W2has been presented as comprising metal bars of circular cross-section, with the first joint surface S1and the second joint surface S2each facing in the axial direction and comprising a flat surface perpendicular to the axial direction. However, provided that the first joint surface S1and the second joint surface S2facing in the axial direction are flat surfaces perpendicular to the axial direction, respectively, there may be used other materials, different outer diameters and shapes, such as a polygonal column.

In the embodiment described above, an example has been presented wherein the cutting step is continuously performed after the friction welding, while rotating the first workpiece W1and the second workpiece W2at the same rotation speed in the same rotation direction as in the heating step and the pressure contacting step. However, the cutting step may be carried out after the friction welding with the rotation speed of the first workpiece W1and the second workpiece W2controlled to be the rotation speed suitable for the friction welding, and subsequently change of the rotation speed of the first workpiece W1and the second workpiece W2to a level suitable for the cutting step. In this case also, the heating step, the pressure joining step and the cutting step can be performed without stopping the rotation of the first workpiece W1and the second workpiece W2, to thereby reduce the processing time.

In the embodiment described above, the pressure joining step has been presented as being carried out with the axes of the first workpiece W1and the second workpiece W2aligned with each other. However, the pressure joining step may be carried out at a position where the axes of the first workpiece W1and the second workpiece W2are unaligned with each other.

REFERENCE SIGNS LIST