Development and Analysis of Ultrasonic Welding Process Using FEM Approach for Aluminum and Copper

Abstract

Ultrasonic welding is a process that uses mechanical vibrations using ultrasonic frequencies. The vibrations are produced by an ultrasonic sonotrode, which is used for joining two thin materials, especially in electronic industries (for applications in battery-making industries). Typically, ultrasonic welding is based on the parameters (frequency range, input pressure/load of the sonotrode, by varying the coefficient of friction between two metal sheets, the thickness of a sheet) while performing the joining process. In this work, the FEA Model-based study is used for analyzing the ultrasonic welding using “Von-Misses stress theory concepts”. The effects of various thickness of the sheet, normal force, coefficient of friction (at different welding conditions) are analyzed while performing the welding process. The temperature variation is studied while using aluminum and copper as thin sheets. This study can be used in the electronic industries for high power ultrasonic welding process, especially using aluminum and copper materials in the form of electrodes, sheets.