ANSYS optimization and design in ultrasonic welding tooling
1 Introduction
With the development of ultrasonic technology, its application is more and more extensive, it can be used to clean tiny dirt particles, and it can also be used for welding metal or plastic. Especially in the current plastic products, ultrasonic welding is mostly used, because the screw structure is omitted, the appearance can be more perfect, and the function of waterproofing and dustproofing is also provided. The design of the plastic welding tool (Horn) has an important impact on the final welding quality and production capacity. In the production of new electric meters, ultrasonic waves are used to fuse the upper and lower faces together. However, during use, it is found that some tools are installed on the machine for a short period of time, such as cracking and other failures, and some tooling welding products The defect rate is high. Various faults have had a considerable impact on production. According to the understanding, equipment suppliers have limited design capabilities for tooling, and often through repeated repairs to achieve design indicators. Therefore, it is necessary to use our own technological advantages to develop durable tooling and a reasonable design method.
2 Ultrasonic plastic welding principle
Ultrasonic plastic welding is a processing method that utilizes the combination of thermoplastics in the high-frequency forced vibration, and the welding surfaces rub against each other to produce local high-temperature melting. In order to achieve good ultrasonic welding results, equipment, materials and process parameters are required. The following is a brief introduction to its principles.
2.1 Ultrasonic plastic welding system
Figure 1 is a schematic illustration of a welding system. The electrical energy is passed through a signal generator and a power amplifier to produce an alternating electrical signal of ultrasonic frequency (> 20 kHz) that is applied to the transducer (piezoelectric ceramic). Through the transducer, the electrical energy becomes the energy of the mechanical vibration, and the amplitude of the mechanical vibration is adjusted by the horn to a suitable working amplitude, and then uniformly transmitted to the material in contact with it through the tool head (welding tooling). The contact surfaces of the two welding materials are subjected to high-frequency forced vibration, and the friction heat generates local high temperature melting. After cooling, the materials are combined to achieve welding.
Figure 1 Schematic diagram of ultrasonic plastic welding system
In a welding system, the signal source is a circuit part that contains a power amplifier circuit whose frequency stability and drive capability affect the performance of the machine. The material is a thermoplastic, and the design of the joint surface needs to consider how to quickly generate heat and dock. The transducer, horn and tool head can all be considered mechanical structures for easy analysis of the coupling of their vibrations. In plastic welding, mechanical vibration is transmitted in the form of longitudinal waves. How to effectively transmit energy and adjust the amplitude is the key point of the design.
2.2 Tool head (welding tooling)
The tool head serves as the contact interface between the ultrasonic welding machine and the material. Its main function is to transmit the longitudinal mechanical vibration outputted by the variator evenly and efficiently to the material. The material used is usually high quality aluminum alloy or even titanium alloy. Because the design of plastic materials changes a lot, the appearance is very different, and the tool head has to change accordingly. The shape of the working surface should be well matched with the material, so as not to damage the plastic when vibrating; at the same time, the first-order longitudinal vibration solid frequency should be coordinated with the output frequency of the welding machine, otherwise the vibration energy will be consumed internally. When the tool head vibrates, local stress concentration occurs. How to optimize these local structures is also a design consideration. This article explores how to apply ANSYS design tool heads to optimize design parameters and manufacturing tolerances.
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