This paper focuses on the development of an effective methodology to determine the optimum welding conditions that maximize the strength of joints produced by ultrasonic welding using response surface methodology (RSM) coupled with genetic algorithm (GA). RSM is utilized to create an efficient analytical model for welding strength in terms of welding parameters namely pressure, weld time, and amplitude. Experiments were conducted as per central composite design of experiments for spot and seam welding of 0.3-and 0.4-mm-thick Al specimens. An effective second-order response surface model is developed utilizing experimental measurements. Response surface model is further interfaced with GA to optimize the welding conditions for desired weld strength. Optimum welding conditions produced from GA are verified with experimental results and are found to be in good agreement.
Ultrasonic horns are tuned components designed to vibrate in a longitudinal mode at ultrasonic frequencies. Reliable performance of such horns is normally associated with the amplitude of vibration, uniformity of vibration amplitude at the working surface and the avoidance of modal participation by non-tuned modes at the operating frequency. In order to maximise vibration amplitude uniformity, standard slotting configurations are included in the horn design. In this work the slot position in the horn is optimised using factorial design of experiments and the mathematical model developed is further interfaced with genetic algorithm. Modal and harmonic analysis of the horn is done using ANSYS software package. It is observed that slotted block horn with optimised slot position vibrates in longitudinal mode with uniform displacement amplitude across the face of the sonotrode.
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