The Effect of the Material and the Geometric Shape of the Waveguides on the Process of Ultrasonic Welding of Plastics

2019 ◽  
pp. 25-32
Author(s):  
S.S. Volkov ◽  
V.M. Nerovnyy ◽  
G.A. Bigus
Keyword(s):  
Welding Process ◽  
Polymeric Materials ◽  
Ultrasonic Welding ◽  
Wave Resistance ◽  
Tool Geometry ◽  
Acoustic Characteristics ◽  
Oscillatory Systems ◽  
Materials Used ◽  
Quality Of Products

This article briefly describes basic elements of machines for ultrasonic welding of plastics and the main materials used for manufacturing elements of ultrasonic waveguide oscillatory systems. A relationship between the amplitude of fluctuations of the welded material and a ratio of wave resistance of the product material and the waveguide tool geometry is examined. It is shown that when welding plastic products of a large thickness, it is practical to use waveguides made from aluminum alloys with a working end face with a diameter of 15 mm. It is established that the closer the acoustic characteristics of the waveguide material and the plastic are, the fuller the transfer of ultrasonic energy is when transiting through the interface of the welded polymeric materials. To assess the distribution of amplitudes of fluctuations in the welded material it is more convenient to use a transmission ratio, which decreases with a decrease in the wave resistance. It is established that the sizes of the working end face of the waveguide are most often defined by the properties, dimensions and geometry of the welded product. The application of the developed recommendations to the choice of material and sizes of the working end face of the waveguide can increase technological reliability of the ultrasonic welding process and improve quality of products.

Study on Design of Welding-Joint and Structure of Welding Based on Ultrasonic Welding Technology

2011 ◽  
Vol 101-102 ◽  
pp. 871-875 ◽  
Author(s):  
Yi Jun Huang
Keyword(s):  
Welding Process ◽  
High Technology ◽  
Ultrasonic Welding ◽  
Design Requirement ◽  
Welding Joint ◽  
Welding Technology ◽  
Welding Spot ◽  
Increase Productivity ◽  
Quality Of Products

Ultrasonic welding is the application of high-technology for welding thermoplastic products. Various thermoplastic parts can be treated by ultrasonic welding without adding any solvent, adhesive or other auxiliaries, which can increase productivity many times, reduce cost and improve the quality of products. Ultrasonic welding technology is being used widely. This article focuses on the application of ultrasonic welding technology, and has a detailed statement of the design of welding spot by using ultrasonic welding technology, the welding structure, the design requirement for ultrasonic welding, and the ultrasonic welding process.

scholarly journals The Influence of Fillers and Dyes on the Quality of Weld Joints at Ultrasonic Welding of Plastics

2020 ◽  
pp. 13-20
Author(s):  
S.S. Volkov ◽  
A.V. Konovalov ◽  
A.L. Remizov
Keyword(s):  
Welding Process ◽  
Ultrasonic Welding ◽  
Climatic Conditions ◽  
Organic Pigments ◽  
Disperse Fillers ◽  
And Performance ◽  
Quality Of Products ◽  
Increased Strength ◽  
The Impact

In this work, the impact of dyes and fillers on the process of heat generation during ultrasonic welding of plastics was studied, which made it possible to influence the weldability and quality of products. Experiments to weld samples of plastics with various concentrations of dyes and fillers were carried out. Based on the experimental data, it was established that the main parameters of the welding process and the properties of the polymer influenced weldability and performance indicators of the weld joint. The nature and the concentration of the dyes and fillers injected into the polymer to obtain certain characteristics and colors had an impact as well. Optimal concentrations that provided the best weldability, strength and quality of the weld products were obtained for fat-soluble dyes and organic pigments (0.1–1.5 g/kg) as well as disperse fillers and inorganic pigments (5–12 g/kg). Types of dyes and fillers and their optimal concentrations for fat-soluble dyes, organic pigments and disperse fillers were determined. Parameters of the process of ultrasonic welding of dyed and filled plastics were defined. It was established that welded products with the recommended optimal concentration and types of dyes and fillers showed the best weldability, increased strength and performance, and could be used longer under various climatic conditions.

Features of the Heating Process in Ultrasonic Welding of Polycarbonate Products under Independent Pressure

2020 ◽  
pp. 54-62
Author(s):  
S.S. Volkov ◽  
A.L. Remizov ◽  
A.S. Pankratov
Keyword(s):  
Welded Joints ◽  
Welded Joint ◽  
Welding Process ◽  
Ultrasonic Welding ◽  
Heating Process ◽  
Mechanism Of Formation ◽  
High Quality ◽  
Acoustic Contact ◽  
Welding Pressure

This paper presents a mechanism of formation of a hard-to-weld polycarbonate joint by ultrasonic welding. The method utilizes internal and external friction occurring in the welded joint area on abutting surfaces due to shear vibrations of the end of the upper part relative to the lower part. A layer of the heated welded material is formed, localized by thickness, in which predominant absorption of the ultrasonic vibrations occurs, which allows one to obtain high-quality and durable welded joints without significant deformation due to the concentration of thermal energy in the welding zone. The effect of independent welding pressure on the strength of the welded joint of polycarbonate is considered. A new method of ultrasonic welding under the conditions of independent pressure is proposed. The method consists of dividing the static welding pressure into two components: the pressure of the acoustic contact in the zone of contact of the waveguide with the product, and the welding pressure that compresses the welded products, with the latter component being lower than the former. In order to obtain high-quality welded joints made of polycarbonate and to prevent displacement of the welded edges during the welding process relative to each other, a special preparation of the welded edges is developed, which allows one part to be moved vertically relative to the other during the welding process. It is established that the quality of welding depends on the speed of movement and the angle of cutting the edges.

scholarly journals Hot embossing of polypropylene micro-tubes into functional tubular components with controlled inner-pore sizes

2018 ◽  
Vol 190 ◽  
pp. 10005
Author(s):  
Jie Zhao ◽  
Yi Qin
Keyword(s):  
Polymeric Materials ◽  
Hot Embossing ◽  
Sem Analysis ◽  
Tool Geometry ◽  
Micro Forming ◽  
Good Reliability ◽  
Low Viscosity ◽  
Automated Handling ◽  
Tubular Components

To meet ever-increasing demands on the micro-components for medical and non-medical applications, a new micro-shaping technology - “hot embossing of micro-tubes”, had been developed for the forming of polymeric tubular micro-components. The paper presents the results from the forming of Polypropylene(PP) micro-tubes with outer diameters of 1.3mm and inner diameters 0.6mm, to achieve various reduced inner-features. The study was effected by combining experiment, numerical simulation and SEM analysis. FE simulation was implemented by using the material data obtained from the material characterisation tests. The forming experiment was conducted with a high-precision hot-embossing machine, developed in-house, with automated handling and good reliability and repeatability. The Polypropylene (PP) micro-tubes were successfully formed into the desired features at the temperatures of 60°C and 100°C respectively. The influences of the parameters/factors, such as tool design, temperature, forming pressure and holding time, on the quality of the shaped parts, are discussed in details. Based on this study, it is concluded that PP is an ideal candidate material among the polymeric materials for hot embossing of tubular micro-components, due to its good ductility, low transition temperature and low viscosity. Keywords: Micro forming, Manufacturing process, Tool geometry

Analysis of Weld Formation in Multilayer Ultrasonic Metal Welding Using High-Speed Images

2015 ◽  
Vol 137 (3) ◽  
Author(s):  
S. Shawn Lee ◽  
Tae Hyung Kim ◽  
S. Jack Hu ◽  
Wayne W. Cai ◽  
Jeffrey A. Abell
Keyword(s):  
High Speed ◽  
Lateral Displacement ◽  
Welding Process ◽  
Lithium Ion ◽  
Ultrasonic Welding ◽  
Fusion Welding ◽  
Tool Geometry ◽  
Weld Quality ◽  
Weld Formation ◽  
Welding Processes

One of the major challenges in manufacturing automotive lithium-ion batteries and battery packs is to achieve consistent weld quality in joining multiple layers of dissimilar materials. While most fusion welding processes face difficulties in such joining, ultrasonic welding stands out as the ideal method. However, inconsistency of weld quality still exists because of limited knowledge on the weld formation through the multiple interfaces. This study aims to establish real-time phenomenological observation on the multilayer ultrasonic welding process by analyzing the vibration behavior of metal layers. Such behavior is characterized by a direct measurement of the lateral displacement of each metal layer using high-speed images. Two different weld tools are used in order to investigate the effect of tool geometry on the weld formation mechanism and the overall joint quality. A series of microscopies and bond density measurements is carried out to validate the observations and hypotheses of those phenomena in multilayer ultrasonic welding. The results of this study enhance the understanding of the ultrasonic welding process of multiple metal sheets and provide insights for optimum tool design to improve the quality of multilayer joints.

Experimental Investigation and Optimization of Friction Stir Welding Process - A Review

2014 ◽  
Vol 550 ◽  
pp. 39-47 ◽  
Author(s):  
K.P. Yuvaraj ◽  
B. Senthilkumar
Keyword(s):  
Experimental Investigation ◽  
Friction Stir Welding ◽  
Welded Joint ◽  
Welding Process ◽  
Tool Geometry ◽  
Weld Quality ◽  
Comprehensive Review ◽  
Friction Stir ◽  
Friction Stir Welding Process

Friction stir welding process parameters plays an important role in determining the quality of welded joint. The weld quality of the joint can be assessed in terms of properties such as lack of defects, tensile strength, hardness and desired microstructure. The objective of the friction stir welding process is to obtain a good welded joint with the desired strength and microstructure. This intended to present comprehensive review of application of tool geometry, different process setups computing techniques, design of experiment (DOE) and evolutionary algorithms used to obtain the good weld joint with desired weld quality.

scholarly journals Selection and Application of Materials in Chemical Machinery Design

2020 ◽  
Vol 213 ◽  
pp. 03005
Author(s):  
Ziyi Xiao ◽  
Zhongfa Du ◽  
Zhejun Huang ◽  
Anyang Tang
Keyword(s):  
Mechanical Properties ◽  
Chemical Production ◽  
Chemical Machinery ◽  
Special Value ◽  
Main Basis ◽  
Materials Used ◽  
Quality Of Products ◽  
Selection Of ◽  
Machinery Design

Materials used in the design of chemical machinery are an indispensable part of industrial production, and chemical machinery materials are also the main basis of chemical production.Chemical mechanical properties can directly determine the quality of products in chemical production, and their materials also determine the quality of chemical mechanical properties. Selecting corresponding materials has become the core of chemical mechanical design.Therefore, in the design of chemical machinery, there is a special value for the selection of materials used in manufacturing.

Friction Stir Welding of Copper Alloy CuETP

2016 ◽  
Vol 716 ◽  
pp. 907-914 ◽  
Author(s):  
Nikola Sibalic ◽  
Milan Vukcevic
Keyword(s):  
Friction Stir Welding ◽  
Welded Joints ◽  
Copper Alloy ◽  
Experimental Studies ◽  
Welding Process ◽  
Mechanical Tests ◽  
Tool Geometry ◽  
Friction Stir ◽  
Sheet Copper

Experimental researches that were performed in order to determine the mechanical parameters in the process of joining of materials using the FSW process are presented in this paper. The paper presents the joining of CuETP sheet copper alloy, with thickness of 5 mm, and provides details of the friction stir welding process. Besides that, the influence of tool geometry and the regime of welding on the quality of welded joints, was investigated. Experimental studies are made on the basis of the adopted multifactoral orthogonal plan, with varying of factors on two levels and repetition in the central point of the plan. Parameters varied in the experiment were: welding speed, rotation speed of tool, angle of pin slope, pin diameter and shoulder diameter. The family of tools is provided, based on the adopted geometric parameters. The experiment was carried out in a laboratory at ambient temperature in conditions similar to those in the production. In order to determine the quality of welded joints, mechanical tests were performed in the paper, and tensile strength and impact toughness were determined.

scholarly journals Effect of tool geometry on ultrasonic welding process

2014 ◽  
Vol 61 ◽  
pp. 012006 ◽  
Author(s):  
Tomohiro Sasaki ◽  
Yutaro Sakata ◽  
Takehiko Watanabe
Keyword(s):  
Welding Process ◽  
Ultrasonic Welding ◽  
Tool Geometry

Effect of ultrasonic welding process parameters on hydrostatic pressure resistance of hybrid textiles for weather protection

2021 ◽  
pp. 004051752098812
Author(s):  
Muktar Seid Hussen ◽  
Yordan Kostadinov Kyosev ◽  
Kathrin Pietsch ◽  
Stefan Rothe ◽  
Abera Kechi
Keyword(s):  
Hydrostatic Pressure ◽  
Process Parameters ◽  
Welding Process ◽  
Preliminary Test ◽  
Ultrasonic Welding ◽  
Welding Parameters ◽  
Hot Air ◽  
Pressure Resistance ◽  
Different Levels

In the research project presented in this paper, the effects of welding width, pressure force, power, and speed of ultrasonic welding parameters on hydrostatic pressure resistance were examined. A flexible and lightweight PVC-coated hybrid textile material with uniform thickness was used for weather protection purposes. Three main welding parameters at three different levels were selected based on the preliminary test results involving welding widths of 6 and 12 mm. A lapped type of seam was applied for ultrasonic welding and conventional joining techniques. A conventionally sewn zigzag seam was produced using three main factors at two different levels according to the application area. To avoid seam permeability, the conventional seam was sealed with tape by means of hot-air tape welding and subsequently investigated regarding its hydrostatic pressure resistance. The hydrostatic pressure resistance value of the conventional seam was then compared with ultrasonic weld seams of 6 and 12 mm welding width, and its parametric influence on the quality of the seam was analyzed. The result shows that the ultrasonic weld seam with a 12 mm welding width provided a higher hydrostatic pressure resistance than the 6 mm welding width and the conventionally sewn seam. Statistical analyses were also carried out to prove the significant effect of welding process parameters on hydrostatic pressure resistance, whereby the obtained results were statistically significant. A suitable nonlinear numerical model was also developed to predict the hydrostatic pressure resistance.

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