Simulation of Static Ultrasonic Welding Based on Explicit Simulation and a More Accurate Representation of the Hammering Effect
Filipp Köhler, Jan Yorrick Dietrich, Irene Fernandez Villegas, Clemens Dransfeld, David May, Axel Herrmann
TL;DR
This paper introduces a new simulation method for ultrasonic welding that better captures the hammering effect, improving accuracy in modeling the welding process for lightweight materials.
Contribution
A novel explicit simulation approach is proposed to more accurately model the hammering effect in static ultrasonic welding.
Findings
The explicit time-domain model effectively represents the static welding process of unidirectional materials with a film energy director.
The simulation results showed strong correlation with experimental thermal behavior at the welding interface.
The sonotrode's neutral position increases during welding due to dynamic stresses, causing disconnection from the upper adherend and energy director.
Abstract
The utilisation of composite materials has the potential to play a vital role in the development of lightweight structures for future generations of aircraft, with the objective to reduce emissions. Ultrasonic welding is a process that has been proven to exhibit advantageous qualities, including the capacity to achieve welds with a comparatively short process time. Furthermore, its capacity to function as both a static and a continuous process makes it a viable candidate for facilitating the realisation of this objective. The present study investigates the potential of a novel explicit modelling approach for the static ultrasonic welding process to more accurately represent the welding process by incorporating a more precise representation of the hammering effect. The hammering effect describes the partial loss of contact between the sonotrode and the upper adherend. The model’s…
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Taxonomy
TopicsAdvanced Welding Techniques Analysis · Mechanical Behavior of Composites · Ultrasonics and Acoustic Wave Propagation