Genetic algorithm ga is used to optimize the welding process parameters. In this work welding parameters like welding pressure, weld time and amplitude of the vibration are considered while producing ultrasonically welded joints of copper. There are a number of parameters that must be selected correctly in order to achieve good ultrasonic welds. Pdf ultrasonic welding is a solidstate joining process that produces joints by the application of highfrequency vibratory energy in the work. Ultrasonic metal welding seminar report, ppt, pdf for. Evaluation of amplitude stepping in ultrasonic welding. Effect of process parameters on strength the spot welding process parameters play an important role for the strength of the welding joint. It is reported t hat welding tool replacement is a major production cost in vehicle battery production.
The 2000xc combines precise and consistent high quality welds, fast cycle. The goal is to identify the proper combination of factors that yield the strongest and best weld attainable using ultrasonic welding. Because of these advances, the process has been developed. Ultrasonic welding is an industrial technique whereby highfrequency ultrasonic acoustic vibrations are locally applied to workpieces being held together under pressure to create a solidstate weld. A typical ultrasonic welding machine consists of a power supply, a converter, a. A number of parameters can affect the welding process, such as ultrasonic frequency, vibration amplitude, static force, power, energy, time, materials, part geometry, and. Analysis of bonding strength of ultrasonic welding process. Changes are made in the type, composition, or physicalmechanical characteristics of the materials used in the parts. Ultrasonic welding an overview sciencedirect topics. Optimization of ultrasonic welding parameters for copper to. The parameters used are not suited to the parts being. However at this stage we look at adjustment and set up of the welding equipment, for which the most important factors are amplitude, clamping force, timing and trigger force. The dominant problem faced by industry dealing with ultrasonic metal welding process is the poor weld quality and strength of the weld due to improper selection of weld parameters. Ultrasonic welding component design and weld parameters twi.
This paper summarizes the current state of joining aluminum alloy by ultrasonic spot welding with numerous critical issues, such as general process parameters, materials flow, interfacial temperature, interfacial shear force, stress distribution, relative motion. This article looks into main aspects of ultrasonic welding of continuous fiber. Ultrasonic welding is an industrial technique whereby highfrequency ultrasonic acoustic vibrations are locally applied to workpieces being held together under pressure to create a. Ultrasonic metal welding ultrasonic metal welding, invented more than 50 years ago, is a process that joins two metals by applying ultrasonic vibrations under moderate pressure. Guidelines for welding thermoplastic materials hot gas hand. Keywords ultrasonic welding, thermoplastic material, process parameters, tensile strength, taguchi orthogonal. Strong bonds can be achieved using ultrasonic welding with most amorphous plastics, given appropriate welding parameters. Ultrasonic metal welding is a solid state joining process which uses ultrasonic vibration to generate oscillating shears between metal sheets clamped under pressure 2. The objective of the present work is to optimize ultrasonic spot welding parameters for joining 3003 aluminum alloy with 304 stainless steel. Ultrasonic welding step by step how ultrasonic welding. At the heart of ultrasonic plasticwelding machines is the transducer assembly often referred to as the stack. Ultrasonic welding produces a localized tem perature rise from the combined effects of elastic hysteresis, interfacial slip, and plastic deforma tion. Ultrasonic welding is also characterised by the quality, strength and accurate reproducibility of the welds. These include vibration amplitude, welding mode, downspeed.
In this research project, friction welding of tubetotube plate using an external tool fwtpet has been performed, and the. Control parameters analysis of ultrasonic plastic welding machine. Effect of ultrasonic welding parameters on microstructure and mechanical properties of dissimilar joints. In ultrasonic metal welding, dissimilar materials are joined together without the use of applied heat or electric current passing through components. Other chapters explore ultrasonic welding, explosion welding, adhesive bonding, thermal spraying and cold spraying, diffusion welding, and diffusion brazing. Friction welding is an important solidstate joining technique. Frontiers ultrasonic welding of thermoplastic composites. Along with the wire electrode, a shielding gas feeds through the welding gun, which shields the process from contaminants in the air. In ultrasonic welding, high frequency vibrations are combined with pressure to join two materials together quickly and securely. Tips on using ultrasonic welding within an automation process. Ultrasonic welding of sensor supports into painted, thinwalled bumpers without spoiling the appearance of the visible side. Tight welding of a panel with a curved surface onto a plastic housing with leds without damage with a carefully designed joining seam. Ultrasonicweldingofhoechst engineeringplastics 5 3. A tack weldis easily broken apart if anything is out of.
Influence of processing parameters on ultrasonic welding. The parameters used are not suited to the parts being joined. Ultrasonic welding is a very fast and energyefficient technique for the joining of thermoplastic composites. A vibration welded air inlet manifold is a common example of large part welding, see figure 4. Ultrasonic welding can join dissimilar metals in a split second, ultrasonic welding eases problematic assembly and this cost effective technique may be key to mass producing fuel efficient. Optimization of ultrasonic welding parameters for copper. Ultrasonic welding, for thermoplastic injection moulded components, is a process that uses mechanical vibrations above the audible range. Ul test certificate provided by tuv for dukane iq ultrasonic generatorpower supplies pdf ultrasonic welding. Experiments are conducted as per taguchi design of experiments. Dukane ultrasonic equipment is manufactured under one or more of the following u. The ultrasonic welding equipment or various welding components are not suited to the application. Ultrasonic welding and assembly of engineering plastics. Effect of welding process parameters on tensile strength.
Ultrasonic energy can weld through contaminates to create a clean seal while providing increased quality and control. The weld is produced without significant melting of the base materials. As a solid joining technique, ultrasonic spot welding is a promising spot welding process to fabricate the aluminum alloy joints. Welding by energy is a closed loop process, giving feedback control. Download data sheets, manuals, drawingslayouts, certifications. The results obtained from experiments are used in the multiple regression analysis and artificial neural. The advantages of ultrasonic welding include the following. Aug 12, 2016 although ultrasonic welding process uses the vibration to create the weld, ultrasonic welding is a different method from vibration welding also known as the friction welding, the acoustic energy createsthe friction, it produces the heat and the parts are welded in less than a second, making it one of the fastest welding methods in use today. Modeling and prediction of weld strength in ultrasonic metal. The process parameters of the models include weld pressure, weld time and amplitude of vibration. In handbook of plastics joining second edition, 2009. Ultrasonic plastic welding is the joining or reforming of thermoplastics through the use of heat generated from highfrequency mechanical motion.
Pdf optimization of ultrasonic welding parameters for. Aop optimum tangential displacement of the sonotrode tip vibration, 10 3 p. Also explore the seminar topics paper on ultrasonic metal welding with abstract or. On optimization of some parameters in ultrasonic metal welding understanding of the weld forming process leads to a way of optimizing some parameters in ultrasonic welding byu. The welding times, applied pressures and temperatures are controlled by a computer or microprocessor within the welding apparatus. The 2000xc locks in the welding process with fully electronic welder settings. Apr 10, 2010 the dominant problem faced by industry dealing with ultrasonic metal welding process is the poor weld quality and strength of the weld due to improper selection of weld parameters. Modeling, sensing and control of gas metal arc welding, 2003. The dominant problem faced by industry dealing with ultrasonic metal welding process is the poor weld quality and strength of the weld due to improper selection of weld. Use of adhesives may create hazardous waste and require protective equipment for personnel. Generally, the quality of a weld joint is directly influenced by the welding input parameters during the welding process.
Characterization and monitoring of tool wear in ultrasonic. Modeling and prediction of weld strength in ultrasonic. These include vibration amplitude, welding mode, downspeed, trigger pressure, weld time, hold time. To obtain these advantages, however, you need to select a readily weldable material, design the joint, design the fixturing and tooling appropriately, design and optimize the welding process and.
Ultrasonic welding usw is a solidstate welding process that produces a weld by local application of highfrequency vibratory energy while the work pieces are held together under pressure. Frisch nomenclature a tangential displacement of the sonotrodetip vibration 103in. Ultrasonic welding is well suited for a large number of automotive components, where high part counts and appropriate strength are required. Ultrasonic laboratory plastics herrmann ultrasonics. The highfrequency vibrations typically 20 khz locally soften the faying surfaces to form a solidstate weld through progressive shearing and plastic deformation. Ultrasonic welding is a solidstate joining process that produces joints by the application of highfrequency vibratory energy in the work pieces held together under pressure without melting. Ultrasonic welding is a solidstate process which produces a weld by the introduction of highfrequency vibration while the weldment is held under moderately high clamping forces. It is accomplished by converting highfrequency electrical energy into highfrequency mechanical motion. In ultrasonic welding, high frequency vibrations are combined with pressure to join. Ultrasonic welding process is most commonly used to join the thermoplastics, it is used in joining the materials which are not similar and it does not require any bolts, soldering. The most important process parameters of vibration welding are frequency, amplitude, pressure, time.
In this work effect of various parameters on weld strength have been studied. The objective is to put the parts into place, align or realign them and to prevent slippage of the material during the structural welding process high speed weld, extrusion weld, etc. The 2000xc combines precise and consistent high quality welds, fast cycle times, and the process control needs of todays manufacturing environment. The nn technique is used to find the importance of individual control parameter. New in this edition is a separate chapter on the developing process variation of friction stir welding. Explore ultrasonic metal welding with free download of seminar report and ppt in pdf and doc format. Optimization of mig welding process parameters for. The objective is to put the parts into place, align or realign them and to prevent slippage of the material during the structural. This paper summarizes the current state of joining. The initial step in the welding process is the tack weld. Ultrasonic welding component design and weld parameters.
The actual approach used in real production to set the ultrasonic welding parameters follows some heuristic steps. Ultrasonic welding thermoplastics were first joined by ultrasonic energy in the late 1960s. That mechanical motion, along with applied force, creates frictional heat at the plastic. Also explore the seminar topics paper on ultrasonic metal welding with abstract or synopsis, documentation on advantages and disadvantages, base paper presentation slides for ieee final year mechanical engineering me or production automobile students for the year 2019 2020. Ultrasonic welding transducers are designed to operate at a specific frequency from 15 to 300 khz for different systems and applications. Sep 30, 2008 a number of parameters can affect the welding process, such as ultrasonic frequency, vibration amplitude, static force, power, energy, time, materials, part geometry, and tooling. The user define some random values of energy, pressure and amplitude generally based on personal experience, then perform the welding operation for the new product. Depending on the application, the welding results depend upon various parameters. Because of these advances, the process has been developed into a practical production tool. On optimization of some parameters in ultrasonic metal welding. Ultrasonic welding usw is a solidstate welding process that produces a weld by local application of high frequency vibratory energy.
In the ultrasonic welding process, industries obtain a poor quality of the welds 5. Patented in 1960, ultrasonic welding for metals, has received significant research and there have been advances in the technology. However, heat sealing is a relatively lengthy and energy inefficient process because of thermal radiation losses when the heated tools are idle. On optimization of some parameters in ultrasonic metal.
Pdf optimization of ultrasonic welding parameters for copper to. Although the ultrasonic metal welding has many advantages including speed, efficiency, long tool life, there are several. A typical ultrasonic metal welding system is shown in fig. Many factors determine the success of an ultrasonic welding process long before it gets to a welder, most notably component materials. In this paper, ultrasonic welding process, ultrasonic weld joint defects and determination of optimal parameters for thermoplastic material had been discussed. It is commonly used for plastics and metals, and especially for joining dissimilar materials.
Analysis of bonding strength of ultrasonic welding process vijay singh pal, pavan agrawal abstract. Process and quality characterization for ultrasonic welding of lithiumion batteries by seungjae lee a dissertation submitted in partial fulfillment of the requirements. Process and quality characterization for ultrasonic welding of lithiumion batteries by seungjae lee a dissertation submitted in partial fulfillment of the requirements for the degree of doctor of philosophy mechanical engineering in the university of michigan 20 doctoral committee. As such, the identified parameters used in this investigation were three, namely. Fundamentals of ultrasonic plastic welding machine design. In ultrasonic welding, highfrequency mechanical oscillations cause molecular and interface friction in the joining zone. For this article, the amplitude and welding modes are considered. Despite the higher initial investment, the speed of ultrasonic welding as a joining process makes it an attractive process during automated production. In this research project, friction welding of tubetotube plate using an external tool fwtpet has been performed, and the process parameters have been prioritized using taguchis l27 orthogonal array. Prediction of industrial process parameters using artificial. Pdf determination of ultrasonic welding optimal parameters for. Controlling the ultrasonic plastic welding process. Ultrasonic energy has been used to join metal materials for decades.
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