Modeling of temperature distribution in ultrasonic welding of thermoplastics for various joint designs

Suresh, K.S.; Rani, Manviri; Prakasan, K.; Rudramoorthy, R.

doi:10.1016/j.jmatprotec.2006.12.028

Cited by 86 publications

(57 citation statements)

References 5 publications

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“…Suresh et al [5] discussed temperature distribution during ultrasonic welding for an amorphous and semi-crystalline thermoplastic for several possible joint designs. In this study, it was found that the measured temperatures at interface are less than simulated results because the viscoelastic dissipation diminishes as the material heats above its glass transition temperature.…”

Section: Introductionmentioning

confidence: 99%

Experimental and theoretical investigations on temperature distribution at the joint interface for copper joints using ultrasonic welding

Elangovan

2014

Manufacturing Rev.

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-Ultrasonic welding is a solid-state joining process that produces joints by the application of high frequency vibratory energy in the work pieces held together under pressure without melting. Copper and its alloys are extensively used in electrical and electronic industry because of its excellent electrical and thermal properties. This paper mainly focused on temperature distribution and the influence of process parameters at the joint interface while joining copper sheets using ultrasonic welding process. Experiments are carried out using Cu sheets (0.2 mm and 0.3 mm thickness) and the interface temperature is measured using Data Acquisition (DAQ) System (thermocouple) and thermal imager. Numerical and finite element based model for temperature distribution at the interface are developed and solved the same using Finite Difference Method (FDM) and Finite Element Analysis (FEA). The results obtained from FDM and FEA model shows similar trend with experimental results and are found to be in good agreement.

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Section: Introductionmentioning

confidence: 99%

Experimental and theoretical investigations on temperature distribution at the joint interface for copper joints using ultrasonic welding

Elangovan

2014

Manufacturing Rev.

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“…A mechanical longitudinal oscillation in the ultrasonic frequency range is coupled in the area of the joint part surface, leading to a vibrational heating of the plastics. The heating mechanism of ultrasonic welding for thermoplastics is mainly based on viscoelastic dissipation under cyclic loading [3][4][5][6]. At the same time a joining force has to be applied.…”

Section: Ultrasonic Welding Of Plasticsmentioning

confidence: 99%

Welding of bio-based plastics for applications in the field of injection moulding

Hopmann¹,

Facklam²,

Schöngart³

2017

AIP Conference Proceedings

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Abstract. Due to intensive research in the field of material development considerable progress in terms of processing and performance characteristics could be achieved during the last years. Therefore, bio-based plastics are increasingly being used for the production of durable injection moulded components. Several applications can be found in the automotive sector, in the field of consumer electronics or the sports industry. For an economic production, joining technology often plays a key role to realise modular designed components. Detachable connections, which are frequently used in plastics processing (e. g. snap hooks or screw connections), often reach their limits with respect to reliability and tightness of the joint. In order to meet the increasing requirements on the joint, plastics joining processes can allow suitable component assembly. Bio-based plastics may differ from conventional plastics regarding their processing properties, such as the melting and solidification behaviour. For these reasons, investigations were carried out to gain extensive process knowledge about the welding of bio-based plastics. To perform a scientific examination of the influence of the moulding process on the mechanical weld seam quality, cellulose and lactic acid based plastics were selected and injection moulded with varying parameters like melt temperature, mould temperature and injection flow rate. In subsequent welding experiments using ultrasonic welding, materially bonded connections have been produced and analysed with regard to mechanical and morphological properties. The investigations show that all of the selected bio-based plastics can be welded. Depending on the material and the welding method the choice of the moulding parameters can have different influences on the weld seam strength. For example, a higher mould temperature during injection moulding can lead to higher weld seam strengths for ultrasonic welded test specimens of lactic acid-based plastics.

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“…The retained parts around the micro-channels and reservoirs were used as energy director to concentrate energy of ultrasonic vibration during bonding. Comparing with traditional point-contact or line-contact energy director (Suresh et al 2007), the area-contact energy director used in this paper has larger contact area, which makes the control of bonding process easier. In order to avoid over-heating caused by high concentrated bonding pressure at intersection portion of energy director, supporting structures with the same height and width as energy directors were fabricated to balance the pressure.…”

Section: Fabrication Of Energy Directormentioning

confidence: 99%

“…The propagation of ultrasonic in polymer generates viscoelastic heat (Tolunay et al 1983). And if the amplitude of ultrasonic vibration is low enough, only facial heat at the surface of energy director is generated as a result of balance between heat generation and thermal conduction (Tolunay et al 1983;Suresh et al 2007).…”

Section: Introductionmentioning

confidence: 99%

A low temperature ultrasonic bonding method for PMMA microfluidic chips

et al. 2010

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Bonding is a bottleneck for mass-production of polymer microfluidic devices. A novel ultrasonic bonding method for rapid and deformation-free bonding of polymethyl methacrylate (PMMA) microfluidic chips is presented in this paper. Convex structures, usually named energy director in ultrasonic welding, were designed and fabricated around micro-channels and reservoirs on the substrates. Under low amplitude ultrasonic vibration, localized heating was generated only on the interface between energy director and cover plate, with peak temperature lower than T g (glass transition temperature) of PMMA. With the increasing of temperature, solution of PMMA in isopropanol (IPA) increases and bonding was realized between the contacting surfaces of energy director and cover plate while no solution occurs on the surfaces of other part as their lower temperature. PMMA microfluidic chips with micro-channels of 80 lm 9 80 lm were successfully bonded with high strength and low dimension loss using this method.

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Modeling of temperature distribution in ultrasonic welding of thermoplastics for various joint designs

Cited by 86 publications

References 5 publications

Experimental and theoretical investigations on temperature distribution at the joint interface for copper joints using ultrasonic welding

Experimental and theoretical investigations on temperature distribution at the joint interface for copper joints using ultrasonic welding

Welding of bio-based plastics for applications in the field of injection moulding

A low temperature ultrasonic bonding method for PMMA microfluidic chips

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