Abstract
A new friction model is built for ultrasonic consolidation process by considering deformation of foils due to the texture on the surface of sonotrode. Based on the friction model, a thermal-mechanical coupled finite elemental model is built to study the influence of process conditions on interface temperature and plastic strain. Study results show that the temperature distribution is mainly decided by the frictional heat generation at the contact interface and the plastic deformation mainly occurs at the top of a new foil where it is in contact with sonotrode. Also the appl ied load will mainly influence the interface plastic deformation and the interface temperature is mainly influenced by sonotrode oscillation amplitude. The sonotrode travel speed will mainly influence the oscillation time, thus influencing the interface temperature and plastic strain.
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