Experimental and numerical studies on ultrasonic welding of dissimilar metals

Satpathy, Mantra Prasad; Sahoo, Susanta Kumar

doi:10.1007/s00170-017-0694-2

Cited by 14 publications

(4 citation statements)

References 21 publications

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“…The cutting surface is much cleaner with no crack and delamination compared with the application of the conventional (titanium, aluminium or stainless steel) cutter. Many researchers have investigated the frequency characteristics of various ultrasonic machines considering the geometrical characteristics of the horn; however, they did not even consider the various geometrical design variables simultaneously [125][126][127]. Ultrasound assistance dramatically reduces the creation of a built-up edge, decreases the cutting forces and lowers the process heat [128].…”

Section: Ultrasonic Cuttingmentioning

confidence: 99%

Current Concepts for Cutting Metal-Based and Polymer-Based Composite Materials

2022

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Due to the variety of properties of the composites produced, determining the choice of the appropriate cutting technique is demanding. Therefore, it is necessary to know the problems associated with cutting operations, i.e., mechanical cutting (blanking), plasma cutting plasma, water jet cutting, abrasive water jet cutting, laser cutting and electrical discharge machining (EDM). The criterion for choosing the right cutting technique for a specific application depends not only on the expected cutting speed and material thickness, but it is also related to the physico-mechanical properties of the material being processed. In other words, the large variety of composite properties necessitates an individual approach determining the possibility of cutting a composite material with a specific method. This paper presents the achievements gained over the last ten years in the field of non-conventional cutting of metal-based and polymer-based composite materials. The greatest attention is paid to the methods of electrical discharge machining and ultrasonic cutting. The methods of high-energy cutting and water jet cutting are also considered and discussed. Although it is well-known that plasma cutting is not widely used in cutting composites, the authors also took into account this type of cutting treatment. The volume of each chapter depends on the dissemination of a given metal-based and polymer-based composite material cutting technique. For each cutting technique, the paper presents the phenomena that have a direct impact on the quality of the resulting surface and on the formation of the most important defects encountered. Finally, the identified current knowledge gaps are discussed.

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Section: Ultrasonic Cuttingmentioning

confidence: 99%

Current Concepts for Cutting Metal-Based and Polymer-Based Composite Materials

2022

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“…Roopa Rani et al studied the displacement, stress, and heat specification of various horns with different cross-sectional shapes through experimental and analytical methods, and Nguyen et al developed a horn with a B-spline cross-sectional shape and further investigated its characteristics [16,17]. In addition, many researchers have investigated the displacement and frequency characteristics of various ultrasonic machines considering the geometrical characteristics of the horn, but it was a single-material ultrasonic horn and blade, and they did not even consider the various geometrical design variables simultaneously [7,[18][19][20][21][22][23][24][25][26].…”

Section: Conceptual Design Of a Sonotrodementioning

confidence: 99%

Optimal Design and Experimental Verification of Ultrasonic Cutting Horn for Ceramic Composite Material

et al. 2021

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We developed and optimized a block-type ultrasonic horn that can be used for cutting hard materials. The proposed block-type sonotrode consists of an aluminum horn and a tungsten carbide blade to increase the cutting of hard materials. We designed an initial ultrasonic block horn that has double slots and an exponential stepped profile. We developed a finite element model of the initial model and analyzed the characteristics of natural frequency and displacement. We formulated a DOE table and response surface to perform sensitivity analysis and analyze the correlation between the design variables and characteristics of the proposed block horn. The optimal ultrasonic block horn was derived via a multi-objective optimal design problem to maximize the amplitude uniformity of the proposed horn and frequency separation. We fabricated the optimal block horn and verified it experimentally. An ultrasonic cutting experiment was conducted to find the ultrasonic cutting force with hard ceramic composite materials. A cutting test with a conventional cutting machine under the same condition was also conducted to compare the cutting force. The proposed optimal ultrasonic cutter requires 70% less cutting force than the conventional cutter to cut a ceramic composite material and the cutting surface with the application of the proposed optimal ultrasonic cutter is much cleaner with no crack and delamination than that with the application of the conventional cutter.

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“…Mehran designed a wide-blade ultrasonic horn based on finite element simulation, and the ultrasonic vibrations were amenable to being evenly distributed on the horn [20]. Satpathy designed a stepped sonotrode to weld thin metal plates by using ANSYS R15.0 and COMSOL 5.2a software, and the results showed that the displacement node was the most vulnerable part [21]. Hameed designed a sonotrode with a characteristic frequency that is greater than that of the transducer, and they found that that sonotrode had a larger amplification factor and a smaller stress distribution than the traditional sonotrode [22].…”

Section: Introductionmentioning

confidence: 99%

Rotating Sonotrode Design for Ultrasonic-Assisted Arc Welding of Metal Materials

Mao,

Yang,

Chen

et al. 2024

Materials

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In the process of the ultrasonic-assisted arc welding of metal materials, traditional ultrasonic application methods, such as the low-frequency impact of ultrasonic horns on a base material, can easily cause the non-fusion defect. In order to solve this problem, a rotating sonotrode with a groove and double thin ends was designed in this study. The ultrasonic vibration is transmitted into the weld pool by the rolling of the sonotrode on both sides of the weld. The resonant frequency was set at 50 kHz. Firstly, based on the Mindlin theory, a rotating sonotrode without a groove was designed by solving the frequency equation and by conducting a finite element simulation. Secondly, the effects of the groove, perforation, and transition mode on the resonant frequency, stress distribution, and amplification factor were investigated by finite element simulation. Finally, the optimum rotating sonotrode with a groove was obtained. The results show that the size of a rotating sonotrode that has a small frequency error can be obtained by using the discrete interval solver method combined with finite element simulation. The groove can significantly reduce the resonant frequency. The stress concentration can be effectively reduced by using the elliptical transition mode. The resonant frequency and amplification factor of a rotating sonotrode with a groove could be effectively adjusted by a method of double-position joint perforation. The final resonant frequency was 49.721 kHz and the amplification factor was 3.02. This study provides an effective design method for a sonotrode with double thin ends and a groove structure.

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Experimental and numerical studies on ultrasonic welding of dissimilar metals

Cited by 14 publications

References 21 publications

Current Concepts for Cutting Metal-Based and Polymer-Based Composite Materials

Current Concepts for Cutting Metal-Based and Polymer-Based Composite Materials

Optimal Design and Experimental Verification of Ultrasonic Cutting Horn for Ceramic Composite Material

Rotating Sonotrode Design for Ultrasonic-Assisted Arc Welding of Metal Materials

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