Y-Series Split-Type Friction Welding Machine: The split-type architecture redefines the new height of friction welding efficiencyIn the field of large workpiece welding, the structural flexibility and welding strength of equipment are the core guarantees for production efficiency. The Y-Series split-type Friction Welding Machine, with its innovative Split design and mature friction welding technology as the core, demonstrates unique advantages in the welding scenarios of long shafts and irregular parts. Its performance highlights become increasingly prominent when compared with various welding equipment.
As an upgraded series of the professional Friction Welding Machine, this split equipment breaks through the space limitations of the traditional integrated friction welding machine. Through the separable spindle and tailstock structure, it can easily accommodate large workpieces with a length of more than 5 meters, solving the rigid constraint on the size of workpieces in traditional equipment. Compared with the
Spot Welding Machine that relies on current welding, it achieves solid-state connection by the heat generated from the high-speed friction of the contact surface. When welding difficult-to-weld materials such as high-strength steel and titanium alloys, the joint strength can reach over 95% of the base material, completely avoiding defects such as false welding and pores. It is particularly suitable for welding load-bearing components such as wind turbine main shafts and machine tool lead screws.
Facing the Butt Welding requirements of long rod-type workpieces, the traditional
Butt Welding Machine has to deal with the problem of residual height of the weld seam after welding, while the Y-Series Split-Type Friction Welding Machine precisely controls the friction pressure and time Achieve a smooth transition of the weld seam, and meet the assembly accuracy requirements without secondary processing after welding, increasing the butt connection efficiency of large workpieces by more than 40%. Unlike the
Seam Welding Machine that pursues continuous sealing, it focuses on the overall butt welding of shaft and rod workpieces. While ensuring that the concentricity error is ≤0.05mm/m, it can complete the firm connection of the entire contact surface with a single welding, significantly reducing the welding process of large components.
Although the
Laser Welding Machine for Steel Ring, which focuses on steel ring welding, has outstanding precision, it has the limitations of low efficiency and high cost in the welding of large-diameter thick-walled steel rings. This split-type friction welding machine can complete the overall butt welding of a 500mm diameter steel ring within 3 to 5 minutes through the combined effect of friction heating and forging force. After welding, the flatness error of the ring surface is controlled within 0.1mm. For the Stud connection requirements on the workpiece surface, although it does not have the dedicated functions of the
Stud Welding Machine, the high-strength joints after Welding can directly process stud holes and be used in conjunction with the subsequent Spot Welding Machine to strengthen the stud periphery, meeting the strength requirements of the composite connection scenario.
Compared with the strength dispersion problem existing in the Welding of large workpieces by the Spot Welding Machine that relies on solder joint connection, the overall weld seam formed by the Y-Series Split-Type Friction Welding Machine can uniformly transfer the load. It is especially suitable for components such as transmission shafts and piston rods that are subject to alternating stress. Compared with the traditional Butt Welding Machine, it does not require filling materials. The connection is achieved through the plastic flow of the material of the workpiece itself. There is no arc light or smoke dust during the welding process, which is more in line with the green production standards. For workpieces that require sealing performance, although they do not have the continuous weld advantage of the Seam Welding Machine, the tightness of the overall butt can meet the requirements of waterproofing and gas proofing through subsequent sealing treatment, expanding the application scenarios.
From the Welding of heavy machinery drive shafts to the butt welding of oil pipelines, from the connection of aerospace special-shaped parts to the manufacturing of nuclear power equipment components, the Y-Series split-type Friction Welding Machine, with the flexibility of the Split structure and the high strength characteristics of friction welding, Become the core equipment in the field of large-scale workpiece welding, ensuring that every friction butt joint is a reliable guarantee for structural stability.
Friction welding is a pressure welding method that uses the heat generated by mutual friction in relative rotational motion when the workpiece contacts the end surface, so that the end reaches the thermoplastic state, and then quickly upsets to complete the welding. The most common friction welding method， When welding two circular cross-section workpieces, first make one workpiece rotate at a high speed about the centerline, and then apply axial pressure to the rotating workpiece to start friction heating. When the specified friction welding time or the specified amount of friction deformation is reached, that is, when the joint is heated to the welding temperature, the transfer of the workpiece is immediately stopped, and a greater axial pressure is applied to perform upsetting welding. Usually, the entire welding process only takes a few seconds.
*The welding quality is good and stable. The rejection rate is about 0.01%, and the rejection rate of flash butt welding is 10%-1.4%.
*High welding productivity.
*The production cost is low, and the power of the welding machine is small and the welding time is short, so it can save electric energy. Compared with flash welding, friction welding can save about 80-90% of electric energy. In addition, the welding margin of the workpiece is small; the workpiece does not need special processing and cleaning before welding; sometimes the welding flash does not need to be removed; there is no need for filling materials and shielding gas. Therefore, the processing cost can be reduced by about 30% compared with arc.
*The friction welding machine is easy to realize automation. Operation and maintenance are simple and easy to master. The work site is clean and there is no harmful gas from sparks and arcs.
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