Today ultrasonic power technique is consider a mandatory technique which is always entered in many processes such as in metal and plastic welding to overcomes many issues, with aided of applying force (pressure) and supplied high frequency vibration, a solid-state weld can be generated by ultrasonic metal welding technique. That give a technique the ability to join not only a small components, whereas also to join thicker specimens, depend on a proper control of matching welding conditions. Therefore a welding performance can be study and compared after designed welding horn to resonance at frequencies of 20 kHz and 40 kHz. The analyses of the designed horn are completed through use a vibration mathematical expressions, modal and harmonic analyses to ensure the weldability due to applying ultrasonic power to the working area and also to compare the performance of joint at using two resonance frequencies of 20 kHz and 40 kHz. The dimensions of the horns were determined to match the selected resonance frequencies, which the lengths were calculated as 132 mm and 66 mm respectively. The analysis of the exciting modal indicates that the axial vibration modes of 19,584Hz and 39,794Hz are obtained in 10th mode, while the two frequency values are recorded 19,600 Hz and 39,800 Hz from the frequency response of the two horns. The weld strength between Al and Cu specimens with a thickness 0.5 mm were evaluated using tensile test, which the analyses were obtained under using different welding pressure and varied amplitudes. The results were recorded within exciting a horn with two different resonance frequencies, show the enhancement of weld strength and quality through control of stepping amplitude, the enhancement means obtain good strength of the weld, reduce sticking horn to specimen, and lower specimen marking.
This research aims to contribute a study of design and simulate the ultrasonic block horn configuration containing two slots in order to satisfy these criteria. The simulation and vibration mode shape characterization for the selected horn profiles are discussed and the analysis is accomplished using ABAQUS commercial software package, whilst the vibration modes are classified using experimental data from 3D Laser Doppler Vibrometer measurements. Modal and harmonic analysis are completed successfully to examine the natural frequency for the tuned horn. It is shown in the block horn design that an optimization of slot position will lead to high enough value of longitudinal mode with large uniformity displacement amplitude and low stress across the face of the horn; this is required in many applications and processes to ensure an adequate power transmit to the working parts sufficiently and effectively.
Today ultrasonic power technique is consider a mandatory technique which is always entered in many processes such as in metal and plastic welding to overcomes many issues, with aided of applying force (pressure) and supplied high frequency vibration, a solid-state weld can be generated by ultrasonic metal welding technique. That give a technique the ability to join not only a small components, whereas also to join thicker specimens, depend on a proper control of matching welding conditions. Therefore a welding performance can be study and compared after designed welding horn to resonance at frequencies of 20 kHz and 40 kHz. The analyses of the designed horn are completed through use a vibration mathematical expressions, modal and harmonic analyses to ensure the weldability due to applying ultrasonic power to the working area and also to compare the performance of joint at using two resonance frequencies of 20 kHz and 40 kHz. The dimensions of the horns were determined to match the selected resonance frequencies, which the lengths were calculated as 132 mm and 66 mm respectively. The analysis of the exciting modal indicates that the axial vibration modes of 19,584Hz and 39,794Hz are obtained in 10th mode, while the two frequency values are recorded 19,600 Hz and 39,800 Hz from the frequency response of the two horns. The weld strength between Al and Cu specimens with a thickness 0.5 mm were evaluated using tensile test, which the analyses were obtained under using different welding pressure and varied amplitudes. The results were recorded within exciting a horn with two different resonance frequencies, show the enhancement of weld strength and quality through control of stepping amplitude, the enhancement means obtain good strength of the weld, reduce sticking horn to specimen, and lower specimen marking.
In this presented work, the employment of artificial neural network (ANN) connected with back propagation method was performed to predict the strength of joining materials that carried out by using ultrasonic spot welding process. The models which created in this study were investigated and their process parameters were analysed. These parameters were classified and set as input variables like for example applying pressure, time of duration weld and trigger of vibrating amplitude while weld strength of joining dissimilar materials (Al-Cu) is set as output parameters. The identification from the process parameters are obtained using number of experiments and finite element analyses based prediction. The results of actual and numerical are accurate and reliability, however its complexity has significant effect due to sensitive to the condition variation of welding processes. Therefore, the needed for an efficient technique like artificial neural network coupled with back propagation method is required to use the experiments as an input data in simulation of ultrasonic welding process, finding the adequacy of modeling process in prediction of weld strength and to confirm the performance of using mathematical methods. The results of the selecting non-linear models show a noticeable potency when using ANN with back propagation method in providing high accuracy compared with other results obtained by conventional models.
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