The proposed hybrid equipment for friction stir welding (FSW) focuses on balancing heavy load capacity and compact size. The kinematics and static compliance of the chosen mechanism are modeled and analyzed. Comprehensive objectives, including kinematic performance, static compliance, and overall machine quality, are considered. On this basis, a scale optimization domain and a compliance-constrained domain are established. A multi-layer grid optimization strategy is then implemented, progressing from the subsystem level to the entire machine to refine the design. Optimal parameters are identified through a detailed search in the size domain. This leads to the definition of three-dimensional design parameters for creating a digital prototype of the hybrid equipment, resulting in a structured hierarchical design method and process.
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