DOI : 10.5228/KSTP.2011.20.3.236͑ G
YZ]GV穢剳暒昷儆击穟箒滆V洢YW劒G 洢Z笾SGYWXX噊G
G
昦愛 娚洪 櫚滊殯 穂枪皪 嵢姢汞 廎然殯洗 击洛空昣 愕 殯洗抆 匶凊洇 瞿昷
G
洛笾枿1· 暖煃殶2· 欪渗昣3· 牢昷勢4· 浶涋岞# G
Friction Welding Process Analysis of Piston Rod in Marine Diesel Engine and Mechanical Properties of Welded Joint
G
H. S. Jeong, C. W. Son, J. S. Oh, S. K. Choi, J. R. Cho
(Received February 22, 2011 / Revised May 3, 2011 / Accepted May 4, 2011) G
Abstract
The two objectives of this study were, first, to determine the optimal friction welding process parameters using finite element simulations and, second, to evaluate the mechanical properties of the friction welded zone for large piston rods in marine diesel engines. Since the diameters of the rod and its connecting part are very different, the manufacturing costs using friction welding are reduced compared to those using the forging process of a single piece. Modeling is a generally accepted method to significantly reduce the number of experimental trials needed when determining the optimal parameters.
Therefore, because friction welding depends on many process parameters such as axial force, initial rotational speed and energy, amount of upset and working time, finite element simulations were performed. Then, friction welding experiments were carried out with the optimal process parameter conditions resulting from the simulations. The base material used in this investigation was AISI 4140 with a rod outer diameter of 280 mm and an inner diameter of 160 mm. In this study, various investigation methods, including microstructure characterization, hardness measurements and tensile and fatigue testing, were conducted in order to evaluate the mechanical properties of the friction welded zone.
G G
Key Words : Piston Rod, AISI 4140, Friction Welding, Process Analysis, Mechanical Properties, Marine Diesel Engine
41# ⇆# ᤊG G
⌊㡆₆ὖ㦮 䞒㓺䏺㦖 㡆㏢㔺㠦 㥚䂮䞮Ⳇ, 㡆㏢
㔺㠦㍲ 䙃⩻㦚 㞚 㔺Ⰶ▪ ㏣㦚 㢫⽋㤊☯䞮⓪
䛞㧊Ⳇ 䞒㓺䏺 ⪲✲⓪ 䞒㓺䏺㦮 ῂ㎇䛞㧊┺.
䞒㓺䏺 ⪲✲㦮 ㌗┾⓪ 䞒㓺䏺 䋂⧒㤊ὒ 㡆ἆ
♮㠊 㡆㏢㔺㠦㍲ ㌳♮⓪ 䙃⩻㦒⪲ 㢫⽋ 㤊☯
㦚 䞮Ⳇ, 䞮┾⓪ 䋂⪲㓺䠺✲ 䞖, 䄺⍻䕛 ⪲✲, 䋂⨃䋂 ㌺䝚䔎㢖 㡆ἆ♮㠊 㢫⽋ 㤊☯㦚 䣢㩚 㤊
☯㦒⪲ ⼖䢮㦚 䞮⓪ 㡃䞶㦚 䞲┺.
䞒㓺䏺⪲✲⓪ ㌗┾㠦 㫆Ⱃ♮⓪ 䋂⧒㤊㧊 㡆
㏢Ṗ㓺㠦 㰗㩧 ⏎㿲♮㠊 㧞㠊 ⌊㠦㍲ ⌟ṗ 㡺 㧒㦚 㧊㣿䞮㡂 ⌟ṗ㦚 㔲䅲㭒㠊㟒 ♮⸖⪲, 㩚㼊
₎㧊 䟻㦒⪲ ⌟ṗ 㡺㧒㦮 㧊☯ 䐋⪲㣿 ὋṚ㧊 䞚㣪䞮₆ ➢ⶎ㠦 㭧㕂Ṗ 㭧Ὃ 䡫㌗㦒⪲ 㩲㧧♮
㠊 㧞┺.
䡚㨂 ㍶㣿 䞒㓺䏺 ⪲✲⓪ ┾㫆㠦 㦮䟊 㧒㼊 䡫㦒⪲ 㩲㧧䞮ἶ 㧞㦒Ⳇ 㩲㧧 Ὃ㩫㦖 ┺㦢ὒ ṯ
XUG ㌆╖䞯ᾦG ⪺㓺⪲㧊㓺G ╖䞯₆㑶㎒䎆G YUG 䞲ῃ䟊㟧╖䞯ᾦG ₆ἚὋ䞯ὒG ╖䞯㤦G ZUG 䡚╖㭧Ὃ㠛G 㠪㰚₆Ἒ㌂㠛⽎G G [UG ൽ䅖㧊㠦㓺䞒G ₆㑶㡆ῂ㏢G
JG ᾦ㔶㩖㧦aG 䞲ῃ䟊㟧╖䞯ᾦG ₆Ἒ㠦⍞㰖㔲㓺䎲Ὃ䞯SG G lTagUUG
穢剳暒昷儆击穟箒滆V洢YW劒G 洢Z笾SGYWXX噊VYZ^G
G Fig. 1 Piston rod shape using marine diesel engine
┺. Ⲓ㩖, ╖䡫 㧎ἶ䔎⯒ Ṗ㡊 䤚 㠛㎡䕛, 䆪ₛ ὒ 㩫㦚 Ệ䂲 䤚 Ⱂ 㡊㻮Ⰲ⯒ 䞲┺. 㣎㠦 䢿㌃Ṗ Ὃ㦚 䞲 䤚 㦧⩻ 㩲Ệ 㡊㻮Ⰲ⯒ 䞮ἶ 㭧Ὃ㦚 Ⱒ
✺₆ 㥚䟊 ❻䢖 ṖὋ㦚 䞲┺.
⡦䞲, ⪲✲㠦 䚲Ⳋ ἓ䢪 㡊㻮Ⰲ⯒ 䞲 䤚 㩫㌃
ṖὋ 㡆Ⱎ Ὃ㩫㦒⪲ 㩲㧧♲┺.
⁎⩂⋮, ╖䡫 䞒㓺䏺 ⪲✲⯒ 㧒㼊䡫㦒⪲ 㩲㧧䞮
┺ ⽊┞ ┺㦢ὒ ṯ㦖 ⶎ㩲㩦㧊 㧞┺. ┾㫆 㭧⨟㧊 䋆 㩲䛞㦮 ἓ㤆 㟓 5.5䏺㠦 ╂䟊 ╖㣿⨟㦮 ┾㫆 䝚⩞㓺(2500䏺 㧊㌗)Ṗ 䞚㣪䞮Ⳇ, 㩲䛞㦮 ₎㧊Ṗ 1.8-4.2m⪲ 㡊㻮ⰂὋ㩫 ☯㞞 Ⱔ㦖 ⼖䡫㧊 ㌳䞮
⸖⪲ Ⱔ㦖 ṖὋ 㡂㥶(25-30mm)⯒ 㩗㣿䞮㡂 㡞゚
䡫㌗㦚 㩲㧧䞮Ⳇ, 㩲䛞 㭧Ṛ 㦮 ❻䢖 ṖὋ㦒
⪲ ṖὋ ㏢㨂 ゚㣿㧊 Ⱔ㧊 ㌳♲┺.
⡦䞲, 㧒㼊䡫 ┾㫆⯒ 䞲 䤚 䛖Ⱂ 㡊㻮Ⰲ㢖 䢿㌃
ṖὋ 䤚㦮 ⥾㧚 㡊㻮Ⰲ ❇㦒⪲ 㡊㻮Ⰲ ゚㣿㧊 Ⱔ㧊
㌳䞮Ⳇ, 㩲䛞㦮 䋂₆Ṗ 䋂ἶ 㭧⨟㧊 Ⱔ㦒⸖⪲ ╖ 㣿⨟㦮 㡊㻮Ⰲ⪲ 䢿㌃ṖὋ 㧻゚Ṗ 䞚㣪䞮┺.
Ⱎ㺆㣿㩧㦖 㧒 㣿㩧㠦 ゚䞮㡂 㡊㡗䟻㦮 ⻪ 㥚Ṗ 㫗ἶ, Ⱎ㺆㣿㩧 㭒㥚㠦⓪ ㏢㎇⼖䡫㧊 㧒㠊
⋮ 㨂⬢ 䔏㥶㦮 ㎇㰞㦚 㥶㰖䞶 㑮 㧞㦒Ⳇ 㩚₆㩖 䟃㣿㩧㠦 ゚䟊 㩗㦖 㠦⍞㰖⪲☚ 㩧䞿㧊 Ṗ⓻䞮┺.
㧊⩂䞲 㡂⩂ Ṗ㰖 㧻㩦㦚 Ṗ㰖ἶ 㧞㠊 㧦☯㹾, 㩚₆, 㫆㍶, 䢪䞯, 㤦㧦⩻ ❇㦮 ㌆㠛㠦㍲ 㤆㑮䞲 䔏㎇㦚 䢲㣿䞮㡂 ὧ⻪㥚䞮Ợ ㌂㣿♮ἶ 㧞┺[1].
䡚㨂₢㰖 Ⱎ㺆㣿㩧㠦 ╖䞲 Ⱔ㦖 㡆ῂṖ 㰚䟟♮
ἶ 㧞┺. Ⱎ㺆㣿㩧㠦 ╖䞲 㑮䂮䟊㍳㧊 ╂♮₆ 㩚㠦⓪ 㑮䂮䟊㍳ ₆⻫㦚 Ṳ䞮₆ 㥚䞲 㡆ῂṖ 㰚䟟♮㠞㦒Ⳇ[2~4], Ⱎ㺆㣿㩧 ☯㞞 ⼖䢪♮⓪ ㏢㨂 㦮 ⁞㏣㩗 ₆Ἒ㩗 䔏㎇ ⼖䢪㠦 ╖䞲 㔺䠮㩗 㡆ῂ☚ Ⱔ㧊 㰚䟟♮ἶ 㧞┺[5~10]. ⡦䞲, Ⱎ㺆㣿㩧 㦚 㧊㣿䞮㡂 ╖䡫 㩲䛞㦚 㩲㧧䞮₆ 㥚䞮㡂 㑮䂮 䟊㍳㦚 㧊㣿䞮㡂 ㎇䡫㧊 Ṗ⓻䞲 Ὃ㩫⼖㑮 㫆Ị㦚 㡞䁷䞮ἶ, 㧊⯒ 㧊㣿䞮㡂 㔲㩲䛞 㩲㧧 ₆Ἒ㩗 䔏㎇ 䘟Ṗ㠦 ╖䞲 㡆ῂṖ 㰚䟟♮ἶ 㧞┺[11~12].
䞒㓺䏺 ⪲✲㦮 㡆ἆ㢖 ⪲✲⯒ Ⱎ㺆㣿㩧㦚 㧊㣿䞮㡂 䞒㓺䏺 ⪲✲⯒ 㩲㧧䞲┺Ⳋ ㏢㨂 Ṗ Ὃ゚㣿㦚 㩞㟓䞶 㑮 㧞┺. ₆㫊㦮 㡊㻮Ⰲ♲ 㭧Ὃ 䕢㧊䝚⯒ 䢲㣿䞮Ⳋ ❻䢖 ṖὋ 䢿㌃ ṖὋ㠦 ╖ 䞲 ㏢㨂゚ ṖὋ゚ ❇㦮 ㌳㌆㤦Ṗ⯒ 㩞Ṧ䞶 㑮 㧞┺. ⁎⩂⋮, Ⱎ㺆㣿㩧㦚 㧊㣿䞮㡂 ╖䡫 㩲䛞㦚 㩲㧧䞮₆ 㥚䟊㍲⓪ ╖㣿⨟ Ⱎ㺆㣿㩧₆Ṗ 㣪ῂ♮
⸖⪲ ㍶䟟㩗㦒⪲ Ⲓ㩖 Ⱎ㺆㣿㩧 䞮㭧㦚 㡞䁷䞶 䞚㣪Ṗ 㧞┺.
⽎ 㡆ῂ⓪ ╖䡫 㭧Ὃ 䕢㧊䝚㠦 ╖䞲 Ⱎ㺆㣿㩧 Ὃ㩫䟊㍳㦚 䐋䟊 Ⱎ㺆㣿㩧 Ὃ㩫 ⼖㑮 ㍶㩫 ㏢ 㨂㦮 ⼖䡫 Ệ☯ 㡞䁷 Ⱎ㺆㣿㩧㦮 ₆Ἒ㩗 䔏
㎇㠦 ╖䞲 㡆ῂ⯒ 㑮䟟䞮ἶ㧦 䞲┺.
#
51# ඟ⢿㘞⇇# Ჹ# ൮⢫# ㍣⇛㑳ಪ#
514# ᩲⳚ❓⢻# ඟ⢿㘞⇇#
㣎ἓ 280mm, ⌊ἓ160mm㦮 䡫㌗㦚 Ṗ㰚 AISI 4140㏢㨂㠦 ╖䞲 Ⱎ㺆㣿㩧 Ὃ㩫㠦㍲ 㣪ῂ♮⓪ 䞮 㭧, 㔲Ṛ ㏢㨂㦮 ⼖䡫 Ệ☯㦚 㡞䁷䞮ἶ㧦 䞲┺.
Ⱎ㺆㣿㩧㦚 䞮₆ 㥚䟊㍲⓪ 䝢⧒㧊䥶 㠦⍞㰖, 1 㹾 Ṗ㞫⩻, 2 㹾 Ṗ㞫⩻㠦 ╖䞲 Ὃ㩫 ⼖㑮✺㦮 㫆 Ị㦚 㞢㞚㟒 䞲┺. Table 1 㠦㍲ 㩲㔲♲ 䝢⧒㧊䥶 㠦⍞㰖, 1 㹾 Ṗ㞫⩻, 2 㹾 Ṗ㞫⩻ ❇㦮 ┺㟧䞲 Ὃ 㩫⼖㑮✺㦮 㫆Ị㦚 ㌂㣿䞮㡂 Ⱎ㺆Ὃ㩫 䟊㍳㦚 㑮 䟟䞮㡖┺.
╖⼖䡫 㡊㩦㏢㎇ 㥶䞲㣪㏢䟊㍳㧊 Ṗ⓻䞲 ㌗㣿 䝚⪲⁎⧾ DEFORM-2D ⯒ 㧊㣿䞮㡂 Ὃ㩫䟊㍳㦚 㑮 䟟䞮㡖┺. AISI 4140 㦮 ⶒⰂ㩗 䔏㎇㧎 㡊㩚╂Ἒ㑮, ἶ㡾㥶☯㦧⩻㠦 ╖䞲 䔏㎇㦖 DEFORM 㠦㍲ 㩲Ὃ 䞮⓪ ⶒ㎇䂮⯒ 㩗㣿䞮㡖┺.
⚦ ㏢㨂㦮 Ⱎ㺆㠦 㦮䟊㍲ 㡊㧊 ㌳♮Ⳇ, ㌳
♲ 㡊㦖 ㏢㨂⌊⪲ 㩚☚ 㡊㩚╂㧊 䡚㌗㧊 ㌳
♮ἶ, 㣎 Ὃ₆㢖 㩧㽟♲ 㦖 ╖⮮㡊㩚╂ 䡚
㌗㧊 ㌳♲┺. Table 2 ⓪ 㡊㩚╂䟊㍳㠦 ㌂㣿♲ ἓ Ἒ㫆Ị✺㧊┺.
YZ_GV穢剳暒昷儆击穟箒滆V洢YW劒G 洢Z笾SGYWXX噊G
G
2 2
2 2
2 Z
Z mr E I
䟊㍳㠦 ㌂㣿♲ ⳾◎㦖 㭧Ὃ䡫䌲㧊Ⳇ, Ⱎ㺆㥚 㦮 䡫㌗㧊 㤦䐋䡫㧊⸖⪲ 㿫╖䃃㦒⪲ 䟊㍳䞮㡖┺.
㔳 (1)⓪ 䝢⧒㧊䥶 㠦⍞㰖⯒ 䚲䡚䞮⓪ 㑮㔳㧊┺.
(1)
㡂₆㍲ E ⓪ 䝢⧒㧊䥶 㠦⍞㰖(N·mm), I ⓪ 䝢⧒
㧊䥶 ὖ㎇⳾Ⲯ䔎(N·mm·s2), ⓪ ṗ㏣☚(rad/sec), m 㦖 䝢⧒㧊䥶 㰞⨟(kg), r 㦖 䝢⧒㧊䥶 ἓ(mm)㧊┺.
Table 1 Simulation parameter condition for friction welding process
Process parameters Simulation
number Flywheel energy (N·mm)
1st force (N)
2nd force (N)
1 2.5E6 3.5E6
2 2.5E6 4.0E6
3 2.5E6 4.5E6
4 3.0E6 4.0E6
5
1.8E9
3.0E6 4.5E6
Table 2 Thermo-mechanical process parameter for FE simulation
Item Value Unit
Room temperature 20 Convection coefficient 0.02 N/mm/sec/
Lubricant heat transfer coefficient 10 N/mm/sec/
Emissivity 0.7 -
Fig. 2 Schematic of friction welding process analysis
Fig. 2⓪ Ⱎ㺆㣿㩧 Ὃ㩫䟊㍳㠦㍲ ㌳♮⓪ 䡚㌗
ὒ ἓἚ㫆Ị㦚 ⽊㡂㭒ἶ 㧞㦒Ⳇ, Ὃ㩫䟊㍳㦖 ┺㦢 ὒ ṯ㧊 䞮㡖┺. Ⲓ㩖 ㌗ ⁞䡫㦖 ㌗ ㏢㨂㢖 䞾℮ 䝢⧒㧊䥶 㠦⍞㰖㠦 㦮䟊 㧒㩫䞲 䣢㩚㧊 Ṗ 䟊㰖Ⳇ 䞮 ⁞䡫㦖 䞮 ㏢㨂㢖 䞾℮ 㩫㩗 ㌗䌲 㠦㍲ 㧒㩫䞲 1㹾 Ṗ㞫⩻㦚 Ṗ䞲┺. ⚦ ㏢㨂㦮 㩧 㽟Ⳋ㠦㍲⓪ Ⱎ㺆㠦 㦮䞲 㡊㧊 ㌳䞮ἶ 㡾☚㦮
㌗㔏㠦 㦮䟊 Ⱎ㺆Ⳋ㠦㍲ ῃ㩗㧎 ⼖䡫㧊 ㌳₊┺.
‶㧒䞲 㡾☚䙂㢖 ⼖䡫㧊 ♮Ⳋ 1㹾 Ṗ㞫⩻⽊┺
▪ 䋆 2㹾 Ṗ㞫⩻㦚 㩗㣿䞲┺. ⚦ ㏢㨂⓪ 㩫㰖㢖
☯㔲㠦 Ⱎ㺆㣿㩧㧊 ♲┺. 㧊⩂䞲 ὒ㩫㦒⪲ 䟊㍳㦚 䞮㡖┺.
515# ൮⢫# ㍣⇛㑳ಪ#
Ⱎ㺆㣿㩧㠦㍲⓪ 㡊㡗䟻㦒⪲ ₆Ἒ㩗 䔏㎇⼖䢪 Ṗ ㌳♮⸖⪲ ┺㦢ὒ ṯ㦖 䔏㎇䘟Ṗ⯒ 㑮䟟䞮㡖
┺.
Ⱎ㺆㣿㩧㦮 㡊㡗䟻 㩧䞿㌗䌲⯒ 䢫㧎䞮
₆ 㥚䟊 ⁞㏣䡚⹎ἓ㦚 㧊㣿䞮㡂 ⹎㎎㫆㰗㦚 ὖ㺆 䞮㡖ἶ, 㩧䞿㠦 ╖䞲 ₆Ἒ㩗 䔏㎇㦚 䘟Ṗ䞮₆ 㥚䟊 㧎㧻, ἓ☚, 䞒⪲ 㔲䠮㦚 㑮䟟䞮㡖┺.
䞒⪲㔲䠮㦖 㡺⏎㔳 䣢㩚 ΐ䧮 䞒⪲㔲䠮₆⯒ 㧊 㣿䞮㡖㦒Ⳇ, 䣢㩚㏣☚⓪ 2500rpm, 䁷㩫⻪㥚⓪ 1ശ 104~1ശ107 ⻪㥚㠦㍲ 㔺䠮䞮㡖┺. ἓ☚㔲䠮㦖 Ⱎ㧊 䋂⪲ ゚䄺㓺⯒ 㧊㣿䞮㡂 㩧䞿㦮 㣿㩧㍶㠦 ╖䞲 㑮㰗䟻㦒⪲ 䁷㩫䞮㡖┺.
61# ൚# ඦ# #
614# ඟ⢿㘞⇇# ൚ඦ#
AISI 4140 ㏢㨂(㣎ἓ 280mm, ⌊ἓ 160mm)㠦 ╖ 䞲 Ⱎ㺆㣿㩧 Ὃ㩫䟊㍳㦚 㑮䟟䞮㡖┺.
Fig. 3㠦 Ⱎ㺆Ὃ㩫 䤚 ⚦ ㏢㨂㦮 㡾☚䙂㢖 㠛
㎡ Ὃ㩫 䤚 㡾☚䙂⯒ ☚㔲䞮㡖┺. Fig. 3(a)⓪ Ⱎ 㺆㠦 㦮䞲 Ṗ㡊┾Ἒ⪲㖾 1㹾 Ṗ㞫⩻ 䤚 ⚦ ㏢㨂 㦮 㡾☚䙂㢖 㞫䞮♲ 䡫㌗㦚 ⋮䌖⌊Ⳇ, Fig. 3(b)
⓪ Ⱎ㺆㠦 㦮䟊 Ṗ㡊♲ ㏢㨂⪲䎆 Ṗ㞫㠦 㦮䟊 㩧䞿┾Ἒ⪲㖾 2㹾 Ṗ㞫⩻ 䤚 㡾☚䙂㢖 㞫䞮♲
䡫㌗㦚 ⋮䌖⌎┺.
Fig. 4㢖 Table 3㦖 Ὃ㩫㔲Ṛ㠦 ➆⯎ ┺㟧䞲 Ὃ㩫
⼖㑮 㫆Ị✺㦮 ἆὒ⯒ ⽊㡂㭒ἶ 㧞┺.
䟊㍳㫆Ị 1-3㦮 ἓ㤆㢖 䟊㍳㫆Ị 4, 5㦮 ἓ㤆⯒
㌊䘊⽊Ⳋ, 1㹾 Ṗ㞫⩻㦖 ṯ㦒⋮ 2㹾 Ṗ㞫⩻㧊 ㌗
╖㩗㦒⪲ 䋆 ἓ㤆 Ὃ㩫㔲Ṛ㦖 ゚㔍䞮⋮ 㩚㼊 㞫 䞮⨟㧊 Ⱔ㞚㰦㦚 㞢 㑮 㧞㠞┺. 䞮㭧㧊 䋊㑮⪳ ㌗
穢剳暒昷儆击穟箒滆V洢YW劒G 洢Z笾SGYWXX噊VYZ`G
G
╖㩗㦒⪲ ⼖䡫㔲䌂 㑮 㧞⓪ ㏢㨂Ṗ Ⱔ₆ ➢ⶎ㦒
⪲ ㌂⬢♲┺.
⡦䞲, 䟊㍳㫆Ị 2, 4㦮 ἓ㤆㢖 3, 5㦮 ἓ㤆⯒ ㌊ 䘊⽊Ⳋ, 2㹾 Ṗ㞫⩻㦖 ṯ㦒⋮ 1㹾 Ṗ㞫⩻㧊 ㌗╖
㩗㦒⪲ 㧧㦖 ἓ㤆 Ⱎ㺆㔲Ṛ㧊 ₎㠊㰦㦚 㞢 㑮 㧞 㠞┺. Ⱎ㺆㔲Ṛ㧊 ₎㠊㰦㠦 ➆⧒ ⳾㨂㠦 㡊㩚╂㧊 Ⱔ㧊 ㌳䞮㡂 ⳾㨂㦮 㡾☚䙂Ṗ ㌗╖㩗㦒⪲ ㌗ 㔏䞮㡂 䝢⧮㓂 ⚦℮Ṗ ㌗╖㩗㦒⪲ 㯳Ṗ䞮ἶ 㩚㼊 㞫䞮⨟㧊 Ⱔ㞚㰦㦚 㞢 㑮 㧞㠞┺.
Fig. 5⓪ 1㹾 Ṗ㞫⩻ 䤚 ㏢㨂㦮 㿫 䟻 㡾☚
䙂⯒ ⽊㡂㭖┺. 1㹾 Ṗ㞫⩻㧊 ㌗╖㩗㦒⪲ 㧧㦖 ἓ㤆
⳾㨂㦮 㡾☚䙂Ṗ ㌗╖㩗㦒⪲ ㌗㔏䞾㦚 ⽊㡂㭖┺.
Table 3㠦㍲ 㩲㔲䞲 Ὃ㩫⼖㑮✺㧊 㩗㣿♲ Ⱎ㺆㣿 㩧 Ὃ㩫䟊㍳㦖 ⳾⚦ 㫡㦖 䟊㍳ἆὒ⯒ 㠑㠞㦒⋮, 䟊㍳㫆Ị 1㦮 1㹾 Ṗ㞫⩻⽊┺ 㧧㦖 Ṗ㞫⩻㧊 㩗 㣿♲ ἓ㤆㠦㍲⓪ Ὃ㩫䟊㍳㦮 Ⱎ㺆 ┾Ἒ㠦㍲ 㩧㽟 Ⳋ㠦㍲㦮 ‶㧒䞲 㡊㌳ὒ 㿿䞲 ⼖䡫㧊 ㌳䞮 㰖 㞠㦢㦚 㞢 㑮 㧞㠞┺.
(a)
G (b)
Fig. 3 (a) Deformation shape and distribution of temperature after friction phase step, (b) Deformation shape and distribution of temperature after upset phase step
Fig. 4 Flywheel energy and displacement curve versus time
Table 3 Simulation results for friction welding process (Øin=160mm, Øout=280mm)
Process parameters
After friction process After upset process Simulation
number Time (sec)
Upset length (mm)
Time (sec)
Upset length (mm) 1 123 4.5 148 19.1 2 123 4.5 146 21.5 3 123 4.5 145 23.9 4 102 4.5 123 17.4 5 102 4.5 121 19.1
Fig. 5 Temperature distribution after friction phase step
Y[WGV穢剳暒昷儆击穟箒滆V洢YW劒G 洢Z笾SGYWXX噊G
G
615# ⎆⣆㔲# ⣆⠻#
AISI 4140 ⽟㏢㨂⯒ 㣎ἓ 280mm, ⌊ἓ 160mm 㧎 㭧Ὃ 䡫㌗㦒⪲ ṖὋ䞮㡂 ㌂㣿䞮㡖┺.
㌂㣿♲ Ⱎ㺆㣿㩧₆⓪ MTI model 400 㧊Ⳇ, 㣿⨟
㦖 400ton 㧊┺. Ὃ㩫䟊㍳㠦㍲ ῂ䞲 2 㹾 Ṗ㞫⩻㧊 䟊㍳㫆Ị 1 㦚 㩲㣎䞮Ⳋ, ⳾⚦ Ⱎ㺆㣿㩧₆㦮 㾲╖
㣿⨟⽊┺ ṯỆ⋮ 䋂Ợ ⋮㢪㦒⸖⪲, 㣿㩧 Ṗ⓻㫆 Ị㦚 ἶ⩺䞮㡂 Table 1 㦮 䟊㍳㫆Ị 1 㦚 ㍶䌳䞮 㡖┺.
Fig. 6㦖 Ⱎ㺆㣿㩧Ὃ㩫㦚 ⽊㡂㭒ἶ 㧞┺. Ⱎ㺆㡊 㠦 㦮䟊㍲ ⚦ ⳾㨂㠦 ㍲㍲䧞 㡊㧊 ㌳䞲 䤚 2 㹾 䞮㭧㦚 Ṗ䞲 䤚 䝢⧮㔲Ṗ 䡫㎇♮⓪ ὒ㩫㦚 ⽊㡂 㭖┺. Fig. 7 㦖 Ⱎ㺆㣿㩧 㢚⬢ 䤚 㧒㼊䢪♲ 䞒㓺䏺
⪲✲ 㔲㩲䛞㦚 ⽊㡂㭖┺. 䟊㍳㫆Ị 1 㦮 ἓ㤆, 㞫䞮
⨟㧊 19.1mm 㧊㰖Ⱒ, 㔲㩲䛞㦮 㞫䞮⨟㦖 21.2mm ⪲ 䁷㩫♮㠞┺. 䟊㍳㫆Ị 2 㦮 㞫䞮⨟ὒ 㥶㌂䞾㦚 㞢 㑮 㧞㠞ἶ, 㧊⓪ 䟊㍳㠦 㦮䟊 㡞䁷♲ 䞮㭧㧊 㔺㩲
⽊┺ ⏨Ợ 㡞䁷♮㠞┺ἶ 䕦┾♲┺.
Fig. 6 Friction welding process for piston rod
Fig. 7 Manufactured piston rod by friction welding
616# ∶⡖# ㍣⇛# 㑳ಪ#
Ⱎ㺆㣿㩧㦮 㡊㡗䟻 㣿㩧㌗䌲⯒ 䢫㧎䞮
₆ 㥚䟊 ⁞㏣䡚⹎ἓ㦚 㧊㣿䞮㡂 ⹎㎎㫆㰗㦚 ὖ㺆 䞮㡖┺. Fig. 8 ⓪ Ⱎ㺆㣿㩧㦮 Ệ㔲㫆㰗 ㌂㰚㦚
⽊㡂㭖┺. 㣿㩧 ἓἚⳊ㠦⓪ Ⱎ㺆㣿㩧㠦㍲ ㌳
♮⓪ ⚦ ㏢㨂㦮 㡊㡗䟻 㦚 䢫㧎䞶 㑮 㧞㠞㦒 Ⳇ, 㣿㩧 㑮㰗┾Ⳋ㠦㍲ 㣿㩧ἆ䞾㧊 㠜㦢㦚 䢫㧎 䞮㡖┺. Fig. 9 ⓪ Ⱎ㺆㣿㩧㦮 ⹎㎎㫆㰗 ㌂㰚㦚
⽊㡂㭖┺. 㣿㩧ἓἚⳊ㦒⪲䎆 ṗṗ 0mm, 5mm, 10mm 㥚䂮㠦㍲㦮 ⹎㎎㫆㰗 ㌂㰚㠦㍲⓪ 㤦㏢㨂⽊
┺ ⹎㎎䞲 Ⱎ⯊䎦㌂㧊䔎 䂾㌗㫆㰗㧊 ὖ㺆♮㠞┺.
㧊⩆ 䡚㌗㦖 2 㹾 Ṗ㞫Ὃ㩫㠦㍲ ㏢㨂㦮 㡊㡗䟻
㠦㍲ ἶ㡾⼖䡫㠦 㦮䞲 㨂ἆ㩫㧊 ㌳♲ 䤚 ἶ㡾
Ṗ 㭒㥚⳾㨂⪲ 㧎䟊 ⌟㧊 ㌳䞮㡂 ㌳㎇♮㠞
┺ἶ ㌂⬢♲┺. 㣿㩧ἓἚⳊ㦒⪲䎆 15mm 㥚䂮㠦
㍲㦮 ⹎㎎㫆㰗 ㌂㰚㧊Ⳇ, 㤦㏢㨂 Ⱎ⯊䎦㌂㧊䔎 㫆 㰗ὒ 㧒䂮䞲 㫆㰗㧊 ὖ㺆♮㠞┺.
Fig. 8 Macrostructures of welded joint part
Fig. 9 Microstructures of welded joint part
穢剳暒昷儆击穟箒滆V洢YW劒G 洢Z笾SGYWXX噊VY[XG
G 㣿㩧㠦 ╖䞲 ₆Ἒ㩗 䔏㎇㦚 䘟Ṗ䞮₆ 㥚䟊
㧎㧻, ἓ☚, 䞒⪲ 㔲䠮㦚 㑮䟟䞮㡖┺.
Fig. 10 㦖 䁷㩫♲ 㧎㧻㔲䠮 ἆὒ⯒ ⋮䌖⌊㠞┺.
㧎㧻ṫ☚, 䟃⽋ṫ☚⓪ 㣿㩧㔲䘎㦮 ἆὒṖ ⳾㨂⽊
┺ ⏨Ợ ὖ㺆♮㠞ἶ, 㡆㔶㥾ὒ ┾ⳊṦ㏢㥾㦖 ⳾㨂 Ṗ ⏨Ợ ὖ㺆♮㠞┺. 㧊⩆ 䡚㌗㦖 㞴㍲ 㠎 䞲 ⌊ 㣿㻮⩒ 㡊㡗䟻㠦㍲ ㏢㨂Ṗ ἶ㡾 ⼖䡫㧊 ㌳♲
䤚 ἶ㡾Ṗ 㭒㥚 ⳾㨂⪲ 㧎䟊 ⌟㧊 ㌳䞮㡂
⌊㦮 㧪⮮㦧⩻㧊 㩲Ệ♮㰖 㞠㞚㍲ ㏢㨂㦮 ṫ☚
Ṗ 㯳Ṗ䞮ἶ, 㡆㔶㥾㧊 Ṧ㏢♲ ộ㦒⪲ ㌂⬢♲┺.
ἓ☚㔲䠮㦖 5kg㦮 䞮㭧㦒⪲ 䞮㡂 1mmṚỿ㦒⪲
㞫㧛㧦⯒ 10㽞 ☯㞞 Ṗ㞫䞮㡂 䁷㩫䞮㡖ἶ, Fig. 11
⓪ 䁷㩫♲ ἓ☚䙂⯒ ⋮䌖⌊㠞┺. Ⱎ㺆㣿㩧㠦 ㌂ 㣿♲ ⳾㨂㦮 ἓ☚ṨṖ ゚㔍䞮Ợ ὖ㺆♮㠞ἶ, Ⱎ㺆 ἓἚⳊ㠦 ➆⧒ ἓ☚㠦 䋂Ợ ⼖䢪Ṗ 㠜⓪ ộ㦒⪲
ὖ㺆䞮㡖┺.
Fig.10 Tensile test results for welded joint
G
Fig.11 Hardness test results for welded joint
Fig.12 Fatigue test results for welded joint
Fig. 12⓪ 䁷㩫♲ 䞒⪲ṫ☚⯒ ⋮䌖⌊㠞┺. ⳾㨂 㢖 㣿㩧 㔲䘎㦮 㾲╖ 䞒⪲ṫ☚⓪ 1ശ107㠦㍲ ṗ ṗ 280MPa, 308MPa㦚 ⋮䌖⌂㦒Ⳇ, 㣿㩧 㔲䘎㦮 䞒⪲ṫ☚Ṗ ⏨Ợ ὖ㺆♮㠞┺.
# 71# ൚# ᤊ#
╖䡫 ❪㩺㠪㰚㠦 ㌂㣿♮⓪ 䞒㓺䏺 ⪲✲(㣎ἓ 280mm, ⌊ἓ 160mm)㠦 ╖䞲 Ⱎ㺆㣿㩧 Ὃ㩫䟊㍳
Ⱎ㺆㣿㩧㦮 ₆Ἒ㩗 䔏㎇㦚 䘟Ṗ䞮㡖┺.
(1) 㾲㩗 Ⱎ㺆Ὃ㩫㫆Ị㦚 㞢₆ 㥚䟊 㡊㩦㏢㎇
㥶䞲㣪㏢⻫㦚 㧊㣿䞮㡂 Ⱎ㺆㣿㩧 Ὃ㩫䟊㍳㦚 㑮 䟟䞮㡖㦒Ⳇ, Ὃ㩫⼖㑮㠦 ╖䞲 㣿㩧 Ṗ⓻㫆Ị㦚 䢫 㧎䞮㡖┺.
(2) Ὃ㩫䟊㍳ ἆὒ⪲䎆 ☚㿲♲ Ⱎ㺆㣿㩧 Ṗ⓻ 㫆Ị䞮㠦㍲ ὖ㎇Ⱎ㺆㣿㩧㦚 ㎇Ὃ㩗㦒⪲ 㑮䟟䞮㡖
┺.
(3) ⁞㏣䡚⹎ἓ㦚 㧊㣿䞮㡂 㣿㩧㌗䌲⯒ ὖ㺆䞮 㡖┺. ㏢㨂㦮 㡊㡗䟻⯒ 䢫㧎䞮㡖ἶ, 㣿㩧ἆ䞾㧊 㠜㦢㦚 䢫㧎䞮㡖┺. ⡦䞲, 㡊㡗䟻㠦㍲ 㤦㏢㨂⽊
┺ ⹎㎎䞲 Ⱎ⯊䎦㌂㧊䔎 䂾㌗㫆㰗㧊 ὖ㺆♮㠞┺.
(4) 㧎㧻, ἓ☚, 䞒⪲ 㔲䠮㦚 䐋䟊 ₆Ἒ㩗 䔏㎇
㦚 䘟Ṗ䞮㡖┺. 㧎㧻 䟃⽋ṫ☚⓪ 㣿㩧㔲䘎㦮 ἆὒṖ ⳾㨂⽊┺ ⏨Ợ ὖ㺆♮㠞ἶ, 㡆㔶㥾ὒ ┾Ⳋ Ṧ㏢㥾㦖 ⳾㨂Ṗ ⏨Ợ ὖ㺆♮㠞┺. 㧊⓪ 㣿㩧㔲䘎 㦮 㡊㡗䟻㠦㍲ ㏢㨂Ṗ ⼖䡫䤚 ⌟㠦 㦮䟊 ㏢ 㨂㦮 ṫ☚Ṗ 㯳Ṗ䞮ἶ, 㡆㔶㥾㧊 Ṧ㏢♲ ộ㦒⪲
㌂⬢♲┺. ⡦䞲, 㾲╖ 䞒⪲ṫ☚⓪ 1ശ107 㠦㍲ ṗ ṗ 280MPa, 308MPa 㦚 ⋮䌖⌂㦒Ⳇ, 㣿㩧 㔲䘎㦮 䞒⪲ṫ☚Ṗ ⏨Ợ ὖ㺆♮㠞┺.
Y[YGV穢剳暒昷儆击穟箒滆V洢YW劒G 洢Z笾SGYWXX噊G
G
㝮 G
㧊 ⏒ⶎ㦖 2010⎚☚ 㩫(ᾦ㥷ὒ䞯₆㑶)㦮 㨂 㤦㦒⪲ 䞲ῃ㡆ῂ㨂┾㦮 㰖㤦㦚 㞚 㑮䟟♲ 㡆ῂ 㧚 (No.K20702001648-10E0100-07010).
Ⳣ ඊ ᯢ 㙶
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[6] H. J. Liu, H. Fujii, M. Maeda, K. Nogi, 2003, Tensile Properties and Fracture Locations of Friction-stir-welded Joints of 2017-T351 Aluminum Alloy, J. Mater. Process. Technol., Vol. 142, pp.
692~696.
[7] A. A. M. d. silva, A. Meyer, J. F. d. Santos, C. E. F.
Kwietniewski, T.R. Strohaecker, 2004, Mechanical and Metallurgical Properties of Friction welded TiC Particulate Reinforced Ti-6Al-4V, Compos. Sci.
Technol., Vol. 64, pp. 1495~1501.
[8] D. G. Lee, K. C. Jang, J. M. Kuk, I. S. Kim, 2004, Fatigue Properties of Inertia dissimilar Friction- welded Stainless Steels, J. Mater. Process. Technol., Vol. 155-156, pp. 1402~1407.
[9] S. Park, K. Um, N. Ma, K. Ahn, K. H. Chung, C.
Kim, K. Okamoto, R. H. Wagoner, K. Chung, 2007, Analysis of Failure Phenomena in Uni-axial Tension Tests of Friction Stir Welded AA6111-T4, AA5083-H18 and DP-Steel, Trans. Mater. Process., Vol. 16, No. 4, pp. 304~308.
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