Thermal modeling during continuous ultrasonic welding

Abstract

Abstract:In this study, a thermal model during continuous ultrasonic welding of thin foils has been developed. The heat generation during the process, stick/slip state, and effect of elastic/plastic strains are included in the formulation. The physics is simplified to a one-dimensional transient heat transfer analysis, the governing equation is nondimensionalized, and important parameters are identified. A fourth-order Runge-Kutta numerical scheme is used to predict the transient temperature as a function of material, constitutive, and process parameters. Comparison with experimental results is provided to justify the assumptions introduced in the model. Different heat generation terms are introduced and their contribution to overall heat generation is presented.

Influence of Horn Misalignment on Weld Quality in Ultrasonic Welding of Carbon Fiber/Polyamide 66 Composite

“…Consequently, the reliable contact between the horn and the workpiece under the horn pressure is extremely important because it affects the ultrasonic wave transmission and energy conversion (Refs. [13][14][15]. Although it is critical to maintain intimate contact between the horn and workpiece, it is conceivable that horn-to-workpiece misalignment may occur because the workpieces may have variations in geometry and dimensions resulting from compression, injection molding, and clamping, which would affect the quality of the welds.…”