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.
In order to study the temperature field (TF) distribution and material flow (MF) in the friction stir welding process, the finite element model of friction stir welding (FSW) was established to simulate the welding process. The temperature field results showed that the temperature on the advancing side (AS) was higher than the retreating side (RS). The temperature field has an important influence on the material flow, so the material flow in the plunging stage and welding stage is simulated numerically to study the material flow trajectory in different stages. The results show that the material distribution is more uniform due to the long time in the plunging stage, and the amount of material flow in the plunging stage is larger than that in the welding stage. In the welding stage, it is found that the shoulder can promote the material flow. After analyzing the displacement of tracking particles in the welding stage, it is found that the displacement of particles on the AS is significantly higher than that on the axis and the RS.
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