Abstract
This article applies to the glue-free bonding of the components made of thermoplastics, specific techniques that use friction heat to plasticize and then join two surfaces. The featured technique is a friction (spin) welding process. Welding parameters were investigated and presented. Spin welding is known to consist of four phases. Analytical calculations were made for the first step. They are focused on the changeability of welding parameters depending on weld velocity. In the next part of this article, calculations including the finite element method were performed. This provided additional data and visualization of the process, which were not available in analytical calculations. Final results of both methods were compared. This made it possible to verify the correctness of theoretical calculations and exactness of FEM analysis.
Highlights
Plastics are known to be molded into various shapes in reasonably simple ways [1]
Melted material flows outside welding interface creating flash. - Rotary friction welding (RFW), in which rubbing between welding surfaces is achieved by rotary movement at least one of the parts (Fig. 2)
Performed calculations have shown that the time of the first phase of friction welding can be approximated by equations written in paragraph 3.1
Summary
Plastics are known to be molded into various shapes in reasonably simple ways [1]. Those methods are known as physical bonding, often referred to welding [2]. Following method shows many advantages over traditional fusion welding techniques: absence of solidification defects, ability to weld dissimilar materials, lack of consumables, ease of automation, cost-effectiveness and eco-compatibility [4]. Such advantages seem to be very attractive to industry. An adhesive is often considered as a weak point in future service scenarios [1] In opposite, it is said, that this friction welding provides joint nearly as strong as the material itself [5]. Following article leads off series of articles focused on friction welding, created for better understanding its process
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