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CN109848355B - Two-section type mechanical-solid phase composite connection method based on semi-hollow rivet - Google Patents

Two-section type mechanical-solid phase composite connection method based on semi-hollow rivet Download PDF

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CN109848355B
CN109848355B CN201910158390.8A CN201910158390A CN109848355B CN 109848355 B CN109848355 B CN 109848355B CN 201910158390 A CN201910158390 A CN 201910158390A CN 109848355 B CN109848355 B CN 109848355B
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rivet
workpiece
workpieces
driving head
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CN109848355A (en
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马运五
李永兵
山河
杨炳鑫
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Shanghai Jiaotong University
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21JFORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J15/00Riveting
    • B21J15/02Riveting procedures
    • B21J15/027Setting rivets by friction heating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21JFORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J15/00Riveting
    • B21J15/02Riveting procedures
    • B21J15/025Setting self-piercing rivets

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Abstract

A two-section mechanical-solid phase composite connection method based on a semi-hollow rivet is characterized in that the semi-hollow rivet and a driving head fixedly connected with a die are coaxially arranged, a groove in a rivet cover is meshed with a boss of the driving head, and the driving head is arranged to drive the driving rivet to be riveted into a material to be connected in a high-speed rotation and low-speed feeding mode in a first process stage; and stopping rotating the rivet in the second stage, feeding at a high speed, avoiding excessive accumulation of heat near the rivet, improving the riveting force, outwards expanding the bottom end of the rivet under the action of deformation resistance of a material to be connected to form mechanical interlocking, eliminating gaps of interfaces between the rivet and the workpiece and between the rivet and the workpiece in the joint under the extrusion action of rapid rivet feeding, and forming solid-phase connection of the interfaces through thermal diffusion at high temperature.

Description

Two-section type mechanical-solid phase composite connection method based on semi-hollow rivet
Technical Field
The invention relates to a technology in the field of material connection, in particular to a two-section type mechanical-solid phase composite connection method based on a semi-hollow rivet.
Background
The point connection of the light alloy member is mainly riveting and friction stir spot welding. The riveting process adopts a stamping mode, so that the rivet and/or the workpiece to be connected are subjected to plastic deformation to form interference interlocking, and mechanical connection is realized. The riveting process is usually carried out at room temperature, and in order to obtain a desired interference interlock effect, a large punching force needs to be applied, the structural strength and rigidity of the riveting equipment, the reliability of the punching driving mechanism, and the strength of the rivet itself are extremely high, and the punch and the die are severely worn. In addition, for light alloys with low ductility at room temperature, such as 7-series aluminum alloy, magnesium alloy, cast aluminum and the like, the large plastic deformation in the riveting process easily causes cracking of the materials, and the joint performance is seriously affected. The friction stir spot welding process generates heat in the workpieces to be connected through the rotation, insertion, withdrawal and other movements of the tool head, and the workpieces to be connected form solid-phase connection under the combined action of the pressure generated by the tool head and the stirring movement. For light alloys that can be heat-treated for strengthening, such as 2-series, 6-series, and 7-series aluminum alloys, the joint strength is severely lost due to the effect of frictional heat softening.
Disclosure of Invention
Aiming at the defects in the prior art, the invention provides a two-section type mechanical-solid phase composite connection method based on a semi-hollow rivet, which improves the interference interlocking effect of mechanical connection by coordinately controlling the rotary motion and the feed motion of the rivet in different process stages, and forms solid phase connection between the rivet and a workpiece and between the workpiece and the workpiece to obtain a mechanical-solid phase composite joint.
The invention is realized by the following technical scheme:
according to the invention, the semi-hollow rivet and the driving head of the fixed connection die are coaxially arranged, the upper groove of the rivet cover is meshed with the boss of the driving head, the driving head is arranged to drive the rivet to rivet into a material to be connected in a high-speed rotation and low-speed feeding mode in the first stage of the process, friction heat is generated by the rotation of the rivet, the temperature of the workpiece to be connected is raised, the cracking of the low-ductility material is avoided, and meanwhile, the riveting resistance of the rivet is reduced so that the rivet reaches the conversion depth in the workpiece to be connected; after the first stage is completed, the rivet is stopped rotating in the second stage and fed at a high speed, so that excessive heat accumulation nearby the rivet is avoided, the riveting force is improved, the bottom end of the rivet is outwards expanded under the action of deformation resistance of a material to be connected to form mechanical interlocking, and simultaneously, under the extrusion action of rapid feeding of the rivet, gaps between the rivet and a workpiece and between the workpiece and the workpiece in a joint are eliminated, and the interface forms solid-phase connection through thermal diffusion at high temperature.
The second stage completes the solid phase joining, that is, when the rivet is fed to a predetermined depth, the driving head is reversely fed and returns to the original position.
The solid phase connection refers to that: and eliminating gaps of each interface near the rivet to realize solid-phase connection of materials on two sides of at least one interface:
① trapping the interface of the metal and the underlying workpiece on the inside of the rivet;
② interface of the outer workpiece of the rivet with the workpiece material;
③ trapping the interface of metal and inner wall of rivet inside the rivet;
④ interface of the outer workpiece material of the rivet with the outer wall of the rivet.
The completion of the first stage is determined according to the thickness and material characteristics of the workpieces to be connected, and the specific requirements are simultaneously met: the rivet has penetrated all but the underlying workpiece, i.e.:
Figure BDA0001983495270000021
wherein: h isiThe thickness of the ith layer of workpiece, n is the number of layers of the connected workpieces, n is more than or equal to 2, D is the conversion depth, and the friction heat fully softens the workpieces to be connected.
The workpieces to be connected comprise at least two layers of workpieces.
The lower layer workpiece is as follows: workpiece positioned above and in contact with fixed connection die
The sufficient softening is determined by any one or combination of the following operations:
a) measuring the temperature of the upper surface of the workpiece to be connected at a position 3-10mm away from the edge of the rivet by adopting an infrared thermometer or a thermocouple and the like, and judging that the material is sufficiently softened when the temperature of the position is increased to 20-50% of the melting point of the workpiece to be connected;
b) measuring the temperature of the center of the upper surface of the fixedly connected die by adopting a manner of embedding a thermocouple and the like, and judging that the material is sufficiently softened when the temperature is increased to 15-30% of the melting point of the workpiece to be connected;
c) measuring the reaction force to which the drive head is subjected, and recording the first peak value F of the reaction force1When the reaction force decreases after the first peakTo 0.3 to 0.6F1When the material is softened sufficiently, the material is judged to be softened sufficiently;
d) measuring the reaction torque to which the drive head is subjected, recording the first peak value M of the reaction torque1When the reaction torque is reduced to 0.3-0.6M after the first peak value1When the material is softened sufficiently, the material is judged to be softened sufficiently;
e) measuring the reaction force and the reaction torque of the driving head, recording the process time, calculating the total energy input E, and when the total energy input E is greater than a preset value E0When the softening of the material is sufficient, the material is judged to be sufficiently softened,
Figure BDA0001983495270000022
wherein: f is the reaction force applied to the driving head, M is the reaction torque applied to the driving head, F is the rivet feed rate of the first stage of the technological process, omega is the rivet rotation speed of the first stage of the technological process, delta t is the technological time, E0The evaluation is made by the thickness and physical properties of the material: e0=C×ρ×H×4πRrivet 2X Δ T, wherein: c is the specific heat capacity of the workpieces to be connected, rho is the density of the workpieces to be connected, H is the total thickness of the workpieces to be connected,
Figure BDA0001983495270000023
n is the number of layers of the workpieces to be joined, RrivetThe radius of the rivet body, Δ T is 2R near the rivetrivetThe average temperature rise of the workpieces to be connected within the range, delta T is 0.2-0.5Tm,TmIs the melting point of the workpieces to be connected;
f) a fixed conversion depth is set based on experimental results and experience.
Furthermore, the first stage of the process can be divided into a plurality of sub-stages with different feeding rates and/or rotating speeds, so that the fine control of heat input is realized, the optimal mechanical-solid phase composite connection effect is obtained, and the sum of the feeding depths of all the sub-stages is the conversion depth D.
The semi-hollow rivet comprises: integrative rivet lid and the rivet body of connecting, wherein: the upper end of the rivet cover is provided with evenly distributed protrusions and/or positioning grooves for transmitting torque.
The rivet body is of a hollow structure, the bottom end of the rivet body is provided with a wedge-shaped taper angle, and the inner wall and the outer wall of the rivet body can be of a smooth structure or structures such as threads and grooves.
The fixedly connecting die comprises: drive head and mould, wherein: the driving head is matched with the groove at the top of the semi-hollow rivet through the boss and is positioned above the workpieces to be connected together, the die is positioned below the workpieces to be connected, and the driving head has the axial linear motion and circumferential rotation motion capabilities.
The position of the upper surface of the fixedly connecting die, which faces the rivet, is provided with a fixing structure for matching the rivet to control the material to flow, and the shape of the fixing structure comprises but is not limited to: flat bottom groove, groove with projection in the middle, flat plate and through hole.
Technical effects
Compared with the prior art, the invention realizes the solid-phase connection between the rivet and the workpiece and between the workpieces on the basis of mechanical connection, thereby improving the overall strength and rigidity of the joint; the workpieces to be connected are softened by reasonably controlling the section conversion depth, so that the riveting force is reduced, and meanwhile, the reliability of mechanical self-locking is improved; the heat input is regulated and controlled through the rivet rotating speed, the feeding rate and the conversion depth of the first stage in the technological process, the heat input is controlled in a required range, the softening caused by friction and heating of the light alloy is fully reduced, the joint is jointly strengthened through the fine-grain strengthening effect generated in the friction stir process, the deformation strengthening effect generated in the rapid feeding of the second stage and the solid-phase connection, the negative influence of the heat softening on the material performance of the connected workpiece is effectively reduced, and the static strength and the dynamic fatigue life of the joint are enhanced.
Drawings
FIG. 1 is a schematic structural view of a semi-blind rivet;
FIG. 2 is a process diagram of the present invention;
in the figure: a is a coaxial matching diagram of the driving head and the semi-hollow rivet; b is a high-speed rotation and low-speed feeding diagram of the semi-hollow rivet driven by the driving head in the first stage of the process; c is a high-speed feeding diagram of the driving head driving the semi-hollow rivet in the second stage of the process; d is feeding the rivet to the final preset depth to form a mechanical-solid phase composite joint diagram; e is the reverse feeding of the drive head back to the bitmap;
FIG. 3 is a schematic view of a mechanical-solid phase composite linker obtained according to the present invention;
in the figure: the semi-hollow rivet comprises a semi-hollow rivet 1, a driving head 2, a fixedly connecting mold 3, a plate to be connected 4, a mechanical-solid phase composite joint 5, a groove 101, a rivet cover 102, a rivet body 103, an upper plate 401, a lower plate 402 and rivet inner side trapped metal 403.
Detailed Description
Example 1
As shown in fig. 2, a specific implementation environment of this embodiment includes: half hollow rivet 1, drive head 2 and link firmly mould 3, wherein: the driving head 2 is matched with the groove 101 at the top of the semi-hollow rivet 1 through a boss and is positioned above the workpieces 4 to be connected together, and the fixed connection die 3 is positioned below the workpieces 4 to be connected.
As shown in fig. 1, a half blind rivet 1 employed in the present embodiment includes: integrally connected rivet cover 102 and rivet body 103, wherein: the central recess 101 of the rivet cover 102 is arranged coaxially with the rivet body 103.
The inner wall and the outer wall of the rivet body 103 are both smooth structures, the inner diameter of the rivet body is 4.3mm, the outer diameter of the rivet body is 5.3mm, and the depth of the rivet body is 4 mm.
The bottom end of the rivet body 103 is provided with a wedge-shaped taper angle 104 with an angle of 45 degrees.
The boss of the driving head 2 and the groove 101 in the center of the rivet cover 102 have the same taper to realize the axial feed motion and the rotation motion of the semi-hollow rivet 1.
The fixed connection die 3 is a concave die with a bulge in the middle, and the height of the central bulge peak of the fixed connection die is flush with the outer edge of the concave die.
And a thermocouple is embedded in the center of the fixed connection die 3, and the time-varying process of the temperature of the center of the upper surface of the die in the technological process is recorded.
The upper plate 401 and the lower plate 402 of the workpiece 4 to be connected are both made of aluminum alloy AA7075-T6, and the thicknesses of the upper plate and the lower plate are both 2.0 mm.
The embodiment specifically comprises the following steps:
1) determining the target temperature of the center of the upper surface of the fixedly connected die 3 corresponding to the conversion depth D in the first stage to be 100 ℃ according to the melting point of the material of the workpiece 4 to be connected;
2) the semi-hollow rivet 1 and the driving head 2 are coaxially arranged by the engagement of the groove 101 on the rivet cover 102 and the boss of the driving head 2;
3) the driving head 2 is axially fed to a position 2mm away from the upper surface of the workpiece 4 to be connected at a linear speed of 50mm/s under the action of a servo motor;
4) the driving head 2 drives the rivet 1 to be riveted into the workpiece 4 to be connected at the rotation speed of 4000r/min and the feeding speed of 2.0mm/s in the first stage of the process, and heat is generated through the friction action between the rivet body 103 and the workpiece 4 to be connected, so that the temperature of the workpiece 4 to be connected is increased, the material is softened, and the riveting resistance is reduced;
5) when the temperature of the center of the upper surface of the fixedly-connected die 3 is raised to 100 ℃ and the feeding depth is 2.0mm greater than the thickness of the upper plate 401, the technological process enters a second stage, the rivet 1 stops rotating, the rivet is fed at a high speed at a speed of 20mm/s, the riveting force is improved, and the bottom end of the rivet body 103 is outwards propped open under the action of the deformation resistance of the workpiece 4 to be connected, so that mechanical interlocking is formed; at the same time, the gap between the inside and outside of the rivet body 103 and the workpieces to be joined 401 and 402 is eliminated by the pressing action of the rivet 1.
6) When the rivet 1 is fed to the predetermined depth of 5.3mm, the driving head is reversely fed, returning to the home position.
As shown in fig. 3, in the finally formed mechanical-solid phase composite joint 5, solid phase connection is formed at three interfaces, including ① interface between the trapped metal 403 inside the rivet 1 and the underlying workpiece 402, ② interface between the rivet body 103 and the trapped metal 403 inside the rivet body, and ③ interface between the rivet body 103 and the underlying workpiece 402 outside the rivet body.
Compared with the prior art, the maximum riveting force of the embodiment in the process of fixedly connecting the aluminum alloy 7075-T6 material with the thickness of 2.0mm is 27.6kN, and is reduced by 55.8% compared with the conventional riveting force of 62.5kN by adopting a traditional self-piercing riveting method.
The average tensile-shear strength of the joint obtained by the embodiment is 470MPa, which is increased by 109% and 31.6% compared with the average tensile-shear strength of the joint obtained by the traditional self-piercing riveting method which is 225MPa and the average tensile-shear strength of the joint obtained by the backfill type friction stir spot welding method which is 357MPa respectively.
Example 2
Compared with the embodiment 1, the upper plate 401 of the workpiece 4 to be connected of the embodiment has a thickness of 2.2mm and is made of the aluminum alloy AA6061-T6, and the lower plate 402 has a thickness of 2.0mm and is made of the magnesium alloy AZ 31B.
Compared with the embodiment 1, the first stage of the process adopted by the embodiment has the rivet rotating speed of 3600r/min, the feeding rate of 1.0mm/s and the second stage has the feeding rate of 11 mm/s.
In contrast to example 1, the conversion depth D of the first stage in this example was determined by thermography measuring the temperature of the upper surface of the upper plate 401 at a distance of 4.0mm from the edge of the rivet, and when the temperature of this point was greater than 125 ℃ and the feed depth was greater than 2.2mm of the upper plate thickness, the process entered the second stage.
Other parameters in this example are the same as in example 1.
Compared with the prior art, the maximum riveting force of the embodiment in the process of fixedly connecting the aluminum alloy AA6061-T6 with the thickness of 2.2mm and the magnesium alloy AZ31B with the thickness of 2.0mm is 14.1kN, and is reduced by 64.8 percent compared with the conventional riveting force of 40.0kN by adopting a traditional self-piercing riveting method.
The average tensile-shear strength of the joint obtained by the embodiment is 198MPa, and is increased by 59.7 percent compared with the average tensile-shear strength of 124MPa of the joint obtained by adopting the traditional self-piercing riveting.
Example 3
Compared with the example 1, the upper plate 401 of the workpiece 4 to be joined of this example was an aluminum alloy AA5182-O having a thickness of 1.5mm, and the lower plate 402 was an aluminum alloy AA5182-O having a thickness of 2.0 mm.
Compared with the embodiment 1, the first stage of the process adopted by the embodiment has the rivet rotating speed of 3000r/min, the feeding rate of 2.0mm/s and the second stage of the process has the feeding rate of 10 mm/s.
The conversion depth D in the present embodiment is empirically set to 2.0mm as compared with embodiment 1.
Other parameters in this example are the same as in example 1.
Compared with the prior art, the maximum riveting force of the embodiment in the process of fixedly connecting the aluminum alloy AA5182-O with the thickness of 1.5mm and the aluminum alloy AA5182-O with the thickness of 2.0mm is 19.9kN, and is reduced by 50.5% compared with the riveting force of 40.2kN in the conventional self-piercing riveting method.
The average tensile shear strength of the joint obtained by the embodiment is 218MPa, which is increased by 26.3% compared with the average tensile shear strength of the joint obtained by traditional self-piercing riveting of 197 MPa; the high cycle pull-pull fatigue life of the joint obtained by the method under the load of 2.3kN is 170 ten thousand, the low cycle pull-pull fatigue life of the joint under the load of 3.5kN is 15 ten thousand, and compared with the fatigue life of the conventional self-piercing riveting joint under the same load, which is 95 ten thousand and 4.4 ten thousand, the fatigue life is respectively improved by 79% and 241%.
Compared with the prior art, the invention has the advantages that: (1) the riveting force required in the process is reduced, the requirements on the structural strength and rigidity of the equipment and the capability of a driving system are reduced, and the loss of the punch and the die in the process is reduced; (2) on the basis of mechanical connection, solid-phase connection of a plurality of interfaces between the rivet and the workpiece and between the workpieces is realized, and the overall strength and rigidity of the joint are improved; (3) the heat input is controlled within a required range, the materials are properly softened, and the joint is jointly strengthened through the fine-grain strengthening effect generated in the stirring friction process, the deformation strengthening effect generated in the second-stage rapid feeding and the solid-phase connection, so that the negative influence of the heat softening on the material performance of the connected workpieces is effectively reduced; (4) the mechanical-solid phase composite connection improves the fatigue life of the joint.
The foregoing embodiments may be modified in many different ways by those skilled in the art without departing from the spirit and scope of the invention, which is defined by the appended claims and all changes that come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.

Claims (7)

1. A two-section type mechanical-solid phase composite connection method based on a semi-hollow rivet is characterized in that the semi-hollow rivet and a driving head of a fixed connection die are coaxially arranged, a groove on a rivet cover is meshed with a boss of the driving head, the driving head is arranged to drive the rivet to be riveted with a material to be connected in a high-speed rotation and low-speed feeding mode in a first process stage, friction heat is generated through rivet rotation, the temperature of a workpiece to be connected is increased, cracking of a low-ductility material is avoided, and meanwhile, the riveting resistance of the rivet is reduced so that the rivet reaches the conversion depth in the workpiece to be connected; after the first stage is finished, stopping rotating the rivet in the second stage, feeding at a high speed, avoiding excessive accumulation of heat near the rivet, improving the riveting force, enabling the bottom end of the rivet to be outwards expanded under the action of deformation resistance of a material to be connected, forming mechanical interlocking, simultaneously eliminating gaps of interfaces between the rivet and a workpiece and between the workpiece and the workpiece in a joint under the extrusion action of rapid feeding of the rivet, and forming solid-phase connection of the interfaces through thermal diffusion at high temperature;
the solid phase connection refers to that: and eliminating gaps of each interface near the rivet to realize solid-phase connection of materials on two sides of at least one interface:
① trapping the interface of the metal and the underlying workpiece on the inside of the rivet;
② interface of the outer workpiece of the rivet with the workpiece material;
③ trapping the interface of metal and inner wall of rivet inside the rivet;
④ interface of the outer workpiece material of the rivet with the outer wall of the rivet;
the completion of the first stage is determined according to the thickness and material characteristics of the workpieces to be connected, and the specific requirements are simultaneously met: the rivet has penetrated all but the underlying workpiece, i.e.:
Figure FDA0002330228590000011
wherein: h isiThe thickness of the ith layer of workpiece, n is the number of layers of the connected workpieces, n is more than or equal to 2, D is the conversion depth, and the friction heat fully softens the workpieces to be connected.
2. The method of claim 1, wherein said sufficient softening is determined by any one or a combination of the following:
a) measuring the temperature of the upper surface of the workpiece to be connected, which is 3-10mm away from the edge of the rivet, by using an infrared thermometer or a thermocouple, and judging that the material is sufficiently softened when the temperature of the point is increased to 20-50% of the melting point of the workpiece to be connected;
b) measuring the temperature of the center of the upper surface of the fixedly connected die by adopting an embedded thermocouple, and judging that the material is sufficiently softened when the temperature is increased to 15-30% of the melting point of a workpiece to be connected;
c) measuring the reaction force to which the drive head is subjected, and recording the first peak value F of the reaction force1When the reaction force is reduced to 0.3-0.6F after the first peak value1When the material is softened sufficiently, the material is judged to be softened sufficiently;
d) measuring the reaction torque to which the drive head is subjected, recording the first peak value M of the reaction torque1When the reaction torque is reduced to 0.3-0.6M after the first peak value1When the material is softened sufficiently, the material is judged to be softened sufficiently;
e) measuring the reaction force and the reaction torque of the driving head, recording the process time, calculating the total energy input E, and when the total energy input E is greater than a preset value E0When the softening of the material is sufficient, the material is judged to be sufficiently softened,
Figure FDA0002330228590000021
wherein: f is the reaction force applied to the driving head, M is the reaction torque applied to the driving head, F is the rivet feed rate of the first stage of the technological process, omega is the rivet rotation speed of the first stage of the technological process, delta t is the technological time, E0The evaluation is made by the thickness and physical properties of the material: e0=C×ρ×H×4πRrivet 2X Δ T, wherein: c is the specific heat capacity of the workpieces to be connected, rho is the density of the workpieces to be connected, H is the total thickness of the workpieces to be connected,
Figure FDA0002330228590000022
n is the number of layers of the workpieces to be joined, RrivetThe radius of the rivet body, Δ T is 2R near the rivetrivetThe average temperature rise of the workpieces to be connected within the range, delta T is 0.2-0.5Tm,TmIs the melting point of the workpieces to be connected;
f) a fixed conversion depth is set based on experimental results and experience.
3. The method as claimed in claim 1, wherein the first stage is divided into several sub-stages with different feed rates and/or rotation speeds, and the fine control of the heat input is realized, so as to obtain the best mechanical-solid phase composite connection effect, and the sum of the feed depths of all the sub-stages is the conversion depth D.
4. The method of claim 1 wherein said semi-blind rivet comprises: integrative rivet lid and the rivet body of connecting, wherein: the upper end of the rivet cover is provided with evenly distributed protrusions and/or positioning grooves for transmitting torque.
5. A method as claimed in claim 4, wherein the rivet body is hollow, the bottom end of the rivet body is provided with a wedge-shaped taper, and the inner and outer walls of the rivet body can be smooth or provided with a thread or groove structure.
6. The method of claim 1 wherein said attachment die comprises: drive head and mould, wherein: the driving head is matched with the groove at the top of the semi-hollow rivet through the boss and is positioned above the workpieces to be connected together, the die is positioned below the workpieces to be connected, and the driving head has the axial linear motion and circumferential rotation motion capabilities.
7. The method as claimed in claim 6, wherein the upper surface of the attachment die is provided with a fastening structure for engaging the rivet to control the flow of material at a location opposite the rivet.
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