Abstract: A portable multi-axis load confirmation tool having a rotating ball on the end thereof follows a three-dimensional weld program path therewith. The ball reacts to an internal load cell for verifying weld program path dynamics before an actual program is run with friction stir welding tools. The load cell is connected to instrumentation electronics converting a load cell signal to a digital readout and comparing the load cell signal to weld program load requirements. The tool integrates into a tool holder loaded on a friction stir welding spindle for simulating an actual friction stir welding tool.

Abstract: A portable multi-axis load confirmation tool having a rotating ball on the end thereof follows a three-dimensional weld program path therewith. The ball reacts to an internal load cell for verifying weld program path dynamics before an actual program is run with friction stir welding tools. The load cell is connected to instrumentation electronics converting a load cell signal to a digital readout and comparing the load cell signal to weld program load requirements. The tool integrates into a tool holder loaded on a friction stir welding spindle for simulating an actual friction stir welding tool.

Abstract: An apparatus and method are provided for measuring loads on a rotating friction stir welding tool of a friction stir welding machine. The apparatus includes a frame that can be connected to the friction stir welding machine, and rollers rotatably connected to the frame are structured to contact and rotate with the friction stir welding tool. Each roller is adapted to adjust in a respective direction and communicate with a respective load cell so that the load cells detect a positional characteristic of the rollers and measure loads applied to the rotating friction stir welding tool during operation. The rollers can contact the rotating tool directly during operation of the machine, such as while the rotating tools is being moved through a workpiece to form a friction stir weld joint, to measure the loads on the tool in the direction of movement of the tool and a direction normal to the movement, i.e., the path and path normal directions.

Abstract: A tool-in-tool device driven by a single power spindle performs multiple operations on a workpiece. The device includes a first tool holder for holding a tool such as a drill, and a second tool holder surrounding mounted on the first tool holder. The second tool holder may hold a second tool such as clamp for clamping the drill to the workpiece, a guide bushing for guiding the drill and a chip breaker for breaking workpiece chips generated by a drilling operation. Multiple interchangeable bushings allow matching the bushing to the size of the drill.

Abstract: Systems and methods for verifying a materials processing path on a work piece are described. In one embodiment, a system for verifying a material process path on a work piece includes a processing unit operable to receive processing instructions to control a motion of a machine tool device relative to a work piece. A tool holder of the machine tool device retains a tool path tracing assembly that applies a mark to a surface of the work piece as the assembly is moved along the material process path.

Abstract: Apparatus for performing operations on a workpiece includes a clamping assembly mounted on a tool support for movement along at least one axis independent of the axes along which the tool moves. The clamping assembly includes clamping devices for applying clamping pressure to the workpiece, and a rotary drive mounted on the tool support for rotating the clamping devices around the independent axis. The clamping devices include clamping packs having a clamping roller mounted on a pneumatically driven slide for applying a programmed amount of clamping pressure to the workpiece.

Abstract: A process control system for a friction stir welding machine employs a master set of parameters and subroutines to control multiple machine processes, including welding, drilling, milling and probing. Sub-sets of the master set comprising command parameters, limits parameters and measurement parameters are used to control the operation of a weld tip, a clamping system and a motion head that cooperate under computer control to carry out the multiple processes.

Abstract: A clamping system can be reconfigured to clamp any of multiple workpieces having differing shapes. The system includes a retention assembly for retaining an inflatable bladder that applies a clamping force to the workpiece. The retention assembly includes a flexible chain of pivotally connected links that can be locked in place to form a rigid assembly that conforms to the shape of the workpiece. The links can be unlocked to allow reconfiguration of the retention assembly into shapes matching other workpieces.