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ETD Abstract Container

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Mechanics and mechanisms of ultrasonic metal welding

de Vries, Edgar
http://rave.ohiolink.edu/etdc/view?acc_num=osu1078415529

Abstract Details

2004, Doctor of Philosophy, Ohio State University, Welding Engineering.
During ultrasonic welding of sheet metal, normal and shear forces act on the parts to be welded and the weld interface. These forces are a result of the ultrasonic vibrations of the tool, pressed onto the parts to be welded. Furthermore they determine the weld quality and the power that is needed to produce the weld. The main goal in this study is to measure and calculate the tangential forces that act on the parts and the weld interface during ultrasonic metal welding and correlate them to weld quality. In this study a mechanics based model was developed which included a model for the temperature generation during welding and its effect on the mechanical material properties. This model was then used to calculate the interface forces during welding. The model results were in good agreement with the experimental results, which included the measured shear force during welding. With the knowledge of the forces that act at the interface it might be possible to control weld quality (strength) and avoid sonotrode welding (sticking of the sonotrode to the parts). Without a solution to these two problems USMW will never be applicable to large scale automated production use, despite its advantages. In the experiments the influence of part dimensions, friction coefficient, normal force and vibration amplitude on weld quality and sonotrode adhesion were examined. The presented model is capable of predicting and explaining unfavorable welding conditions, therefore making it possible to predetermine weld locations on larger parts or what surface preparation of the parts to be welded would lead to an improved welding result. Furthermore shear force at the anvil measured during welding could be correlated to changing welding conditions. This is a new approach of explaining the process of USMW, because it is based on mechanical considerations. The use of a shear force measuring anvil has the potential to be implemented into welding systems and the shear force would provide an additional means of process control.
Karl Graff (Advisor)
253 p.
Engineering, Industrial
Ultrasonic Metal Welding; Ultrasonic Welding; Aluminum Welding; Solid State Welding

Recommended Citations

Citations

  • de Vries, E. (2004). Mechanics and mechanisms of ultrasonic metal welding [Doctoral dissertation, Ohio State University]. OhioLINK Electronic Theses and Dissertations Center. http://rave.ohiolink.edu/etdc/view?acc_num=osu1078415529

    APA Style (7th edition)

  • de Vries, Edgar. Mechanics and mechanisms of ultrasonic metal welding. 2004. Ohio State University, Doctoral dissertation. OhioLINK Electronic Theses and Dissertations Center, http://rave.ohiolink.edu/etdc/view?acc_num=osu1078415529.

    MLA Style (8th edition)

  • de Vries, Edgar. "Mechanics and mechanisms of ultrasonic metal welding." Doctoral dissertation, Ohio State University, 2004. http://rave.ohiolink.edu/etdc/view?acc_num=osu1078415529

    Chicago Manual of Style (17th edition)

osu1078415529
16,776
© 2004, all rights reserved.
This open access ETD is published by The Ohio State University and OhioLINK.