A Numerical Analysis of the Temporal and Spatial Temperature Development during the Ultrasonic Spot Welding of Fibre-Reinforced Thermoplastics

Failure modes of ultrasonic welding joints were investigated by using glass fiber/polyetherimide (PEI) composite material as a base material, and the mechanism of welding pressure with different failure modes and the effects of failure modes on joint strength were explored. The results demonstrate that ultrasonic welding joints have six failure scenarios. Peeling of PEI film and the base material surface on both sides, peeling of PEI film and the base material surface on one side, peeling of surface fiber and surface resin, laminate delamination, fiber breakage, ablation damage respectively. The welding pressure mainly affects the proportion of the first three failure modes. When the welding pressure increases, the proportion of the second failure mode is obvious, meantime the proportion of the first failure mode gradually decreases, the welding pressure mainly affects the proportion of the first three failure modes.The welding joint failure is often a mixed failure generated by the coupling of the abovementioned six failure modes rather than a single failure mode. The evolution of heat distribution with P w was simulated using COMSOL. The simulation curves represent the evolution of the weld interface temperature at different position.

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“…This heat is a volumetric quantity and is related to the matrix loss modulus

E_{m}^{''} (T)

of the viscoelastic material. The amount of heat

{\overset{q}{true}}_{m}

generated by viscoelastic damping per unit time and per unit volume can be expressed by Equation (), where

ε_{m 0}

is the strain component in the matrix 29

{\overset{q}{true}}_{m} = α 2 \frac{ω E_{m}^{''} ε_{m 0}^{2}}{2}

…”

Section: Methodsmentioning

confidence: 99%

Ultrasonic welded joint failure mode of glass fiber/polyetherimide composites

Wang

Xiao

Song

et al. 2023

J of Applied Polymer Sci

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“…28 This generation of heat and the following temperature changes substantially influence the quality of welded joints. 29 COMSOL Multiphysics software models and simulate the temperature and stress distribution of thermoplastic specimens with thicknesses of 2 mm during ultrasonic welding. Using the COMSOL reference module, components are modeled, and element types are selected based on the kind of analysis.…”

Section: Temperature and Stress Distribution Analysismentioning

confidence: 99%

Submerged ultrasonic plastic welding: A computational and experimental investigation

Bose

Prakash

Chelladurai

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part L:

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Thermoplastics hold utmost importance in the day-to-day life of modern-day society, being widely employed in water transport and storage vessels commonly made from thermoplastics such as PVC, i.e., polyvinyl chloride, and PP, i.e., polypropylene. This urge for a joining technique is applicable even with water in the vessel or the submerged case. The present investigation explores ultrasonic welding as an option to weld thermoplastics in water-submerged conditions. We have performed FEM simulations and experimental validation to prove the viability of the proposed ultrasonic welding process used in welding PVC and PP in water-submerged conditions. The discussed results demonstrate a decrease in melting and degradation of adherend material at the weld interface while welding PVC and PP in water-submerged conditions and attaining 65.78% and 107% of weld strength, unlike their open-air counterparts, respectively.

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“…Possible applications are the assessment of highfrequency mechanical loadings the identification of critical operation scenarios of endodontic instruments made of PEEK [11,12]. Furthermore, the knowledge obtained can be used to validate simulations for ultrasonic welding of neat and fiber-reinforced thermoplastic [17,18].…”

Section: Implications For the Design Of Dynamically Loaded Peek Struc...mentioning

confidence: 99%

“…In addition to its high thermal resistance, the polymer PEEK has low material damping compared to other thermoplastics (compare reference [15]). Furthermore, manufacturing processes could also involve dynamic loading, as in ultrasonic welding processes investigated by Abdulfattah et al [16] and Tutunjian et al [17,18] or in high-speed dry milling researched by Song et al [19].…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigation of the Vibration-Induced Heating of Polyetheretherketone for High-Frequency Applications

Kucher

Dannemann

Hedayati

et al. 2023

Solids

Self Cite

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Dynamically loaded structures made of thermoplastic polymers have been extensively exploited in several demanding industries. Due to the viscoelastic and thermal properties of thermoplastic polymers, self-heating is generally inevitable, especially during dynamic deformations at high frequencies. Therefore, the thermoplastic polyether ether ketone (PEEK), with its high temperature resistance and high specific strength, is a particularly ideal candidate for dynamically loaded applications. Using scanning laser Doppler vibrometry and infrared thermography, an experimental study of the vibration characteristics and the vibration-induced heating of flat-sheet PEEK specimens was carried out. The specimens were base-excited by means of a piezoelectric actuator at high frequencies in the range between 1 and 16 kHz. As a result, a maximum temperature rise of approximately 6.4 K was detected for the highest investigated excitation. A high correlation between the spatial distribution of the velocity along the beam’s axial direction and the resulting temperature increase was measured. To summarize, the occurring self-heating of PEEK due to the dissipation of vibrational energy has to be critically considered for dynamically loaded structural applications, especially areas with high displacement amplitudes, such as antinodes, which yield the highest temperature increase.

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A Numerical Analysis of the Temporal and Spatial Temperature Development during the Ultrasonic Spot Welding of Fibre-Reinforced Thermoplastics

Cited by 7 publications

References 34 publications

Ultrasonic welded joint failure mode of glass fiber/polyetherimide composites

Ultrasonic welded joint failure mode of glass fiber/polyetherimide composites

Submerged ultrasonic plastic welding: A computational and experimental investigation

Experimental Investigation of the Vibration-Induced Heating of Polyetheretherketone for High-Frequency Applications

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