A Study on a Novel Process Combines Cutting and Joining by an Automatic Lathe

Abstract

The Swiss-type automatic lathe is designed for continuous mass production of the same product. In the research, the authors propose a combined turning process in which a joining process using the frictional welding method is introduced into the automatic lathe. If the joining process is performed with a Swiss-type automatic lathe, it is expected that the problem of a large amount of residual material due to the mechanical structure can be solved. Generally, the friction welding method is performed by a dedicated machine and is pressure controlled by a hydraulic power source, however in the case of an automatic lathe, friction welding is controlled by the feed length and feed rate. The low rigidity of automatic lathes is also concerned. In the study, the authors investigated the tensile strength and rotational bending fatigue strength of the A6061 bonding material to investigate and quantitatively evaluate the optimum friction welding conditions that can obtain good bonding results in the friction welding method using a multi-axis automatic lathe. Upset speed was the most influential factor for tensile strength and friction rotation speed was good at about 4000 rpm. This fact suggests that excessive heat input leads to a decrease in tensile strength. The tensile strength was equivalent to that of the annealed material. It also seems that the air-cooled annealing phenomenon occurs during the friction welding process. The results of rotational bending fatigue strength were similar to those of the annealed material. It is clarified that friction welding with an automatic lathe is feasible, however, the strength of the bonded material is reduced to the same level as that of the annealed material.