研究目的
To develop a new efficient method with on-machine measurement (OMM) system based on 2D laser profilometer for controlling gap width in friction stir welding (FSW) to improve welding quality.
研究成果
The OMM system based on 2D laser profilometer is efficient in improving the accuracy and uniformity of the assembling gap width for 5-axis FSW. The experimental results show significant improvement in the standard deviation and range of gap width after compensation.
研究不足
The method may not compensate all errors led by tool deformation due to varying milling depth in compensated machining. The distinguishability of the laser profilometer in its X direction causes a jitter in boundary point recognition.
1：Experimental Design and Method Selection:
The method involves kinematics and calibration analysis to establish the transform relationship from laser sensor coordinate system to workpiece coordinate system (WCS), an automatic recognition algorithm to obtain width information, and a compensation strategy based on measurement results.
2：Sample Selection and Data Sources:
The experiment involves tank bottom workpieces designed to be 1/8 of the tank bottom with a largest diameter of 3350mm and an average thickness of about 4mm.
3：List of Experimental Equipment and Materials:
The OMM system includes an on-machine clamp, laser sensor, and the FSW tool. A 2D laser profilometer with a measurement range of 62mm in X direction and distinguishability of 0.02mm is used.
4：02mm is used.
Experimental Procedures and Operational Workflow:
4. Experimental Procedures and Operational Workflow: The process includes calibration of the laser profilometer, scanning of the FSW gap, recognition of boundary points, and compensation milling based on the measurement results.
5：Data Analysis Methods:
The data from the laser profilometer is analyzed using an automatic recognition algorithm to identify boundary points of the welding gap, and the results are used to generate a compensated milling tool path.
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