Abstract
Ultrasonic welding has been used in the market over the past thirty years and offer to the manufacturing industries like automotive, aviation, medical and many more due to various hurdles faced by conventional fusion welding or crimp processes. Very short time (less than 1 second) and no additional material during the connection process are very key advantages. Due to this fact this technology can be used for mass production. Plenty of times, the problems faced by industry due to this process are the poor weld quality and strength of the joints surface. In presented study, the process parameters like vibration amplitude, weld pressure and weld time are considered in analysis of the welding of copper wires (Cu- ETP1). Experiment is conducted according to the fractional design with replications to get the responses like tensile shear stress and T-peel stress of the weld. Measured data are utilized next to develop fuzzy logic model between responses and predictors. As a quality is an very important issue in these manufacturing industries, the optimal combinations of studied process parameters are found using fuzzy logic approach.
Highlights
Ultrasonic welding (USW) is a promising method for joining of softer type metals – in this case copper
The ultrasonic welding involves a number of process parameters which can influence the welding performance characteristic
To remove a certain degree of elusiveness the responses are normalized. Another reason behind the normalization process is that the membership function curve depend on the mapping on the input variables in its of 0 – 1
Summary
Ultrasonic welding (USW) is a promising method for joining of softer type metals – in this case copper. The USW method has been developed between the 1940 and 1950s [1]. In ultrasonic welding method two metals surfaces are joined due to the friction like relative motion between them with a clamping pressure. During this motion the local surface roughness, contaminants and oxides present over it, deform and disappear and make metal to metal connection possible – see illustration of USW process shown in Fig. 1a) and 1b)
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