As the thickness of the friction stir welding plate increases

the bearing capacity of the equipment cannot meet the requirement of high forging force of unilateral friction stir welding

so it is difficult to form a good quality weld. To reduce the forging force on the equipment

a dual-robot mirror friction stir welding process is proposed in this paper. The variation and influencing factors of the forging force are studied

and the feasibility and superiority of the process are verified. Firstly

a thermodynamic coupling finite element simulation model is established to obtain the variation law of the forging force with plate thickness

and the conclusion that the dual-robot mirror friction stir welding process can reduce the forging force is obtained. After that

the forging force estimation model is established

and the experimental correction and verification of the model based on data-driven is carried out to realize sensorless forging force monitoring. Finally

the mirror welding experiment

three-group process parameter multi-factor experiment

and unilateral friction stir welding comparison experiment are carried out on the prototype platform. The variation of the forging force with time and process parameters is obtained

and it is proved that the dual-robot mirror friction stir welding process can reduce the forging force on the stirring head and the bearing capacity requirement of the equipment.