Temperature and stress distribution in ultrasonic metal welding—An FEA-based study |
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| Authors: | S Elangovan S Semeer K Prakasan |
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| Affiliation: | 1. Center for Composite Materials, University of Delaware, Newark, DE 19716, United States;2. Army Research Laboratory, Aberdeen Proving Ground, MD 21005, United States;1. Shenzhen Key Laboratory of Advanced Materials, Shenzhen Graduate School, Harbin Institute of Technology, HIT Campus, Shenzhen University Town, Xili, Nanshan, Shenzhen 518055, PR China;2. State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, 92 Xidazhi Street, Harbin 150001, PR China;1. Department of Materials Science and Engineering, The Ohio State University, Columbus, OH 43221, USA;2. Department of Engineering Technology and Department of Mechanical and Aerospace Engineering, Old Dominion University, Norfolk, VA 23529, USA |
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| Abstract: | In ultrasonic welding, high frequency vibrations are combined with pressure to join two materials together quickly and securely, without producing significant amount of heat. During ultrasonic welding of sheet metal, normal and shear forces act on the parts to be welded and the weld interface. These forces are the result of ultrasonic vibrations of the tool, pressed onto the parts to be welded. In this study a model for the temperature distribution during welding and stress distribution in the horn and welded joints are presented. With the knowledge of the forces that act at the interface it is possible to control weld strength and avoid sonotrode welding (sticking of the sonotrode to the parts). The presented finite element model is capable of predicting the interface temperature and stress distribution during welding and their influences in the work piece, sonotrode and anvil. The study also included the effect of clamping forces, material thickness and coefficient of friction during heat generation at the weld interface. |
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