Abstract
Ultrasonic plastic welding (UPW) is a promising method for joining carbon fiber reinforced thermoplastic (CFRTP). The interface temperature determines weld quality to a large extent. This paper numerically analyzes the contact behavior and temperature characterization during welding using harmonic balance method (HBM). The simulation and experimental results show that amplitude and welding time are important factors determining the interface temperature. Increasing amplitude and welding time can significantly increase the interface temperature. Plunging speed and trigger force have little effect on the interface temperature. For nonlinear contact and heat generation, the results show that there is a certain separation between workpieces and the heat source is mainly friction heat generation in the early stage of welding. With the progress of welding, there is no separation between the workpieces and viscoelastic heat generation begins to dominate.
Highlights
Lightweight materials can effectively reduce fuel consumption and exhaust emissions in the transportation domain, which is of great significance for environmental protection [1,2]
The development of ultrasonic sequential welding and ultrasonic continuous welding has greatly promoted the application of ultrasonic welding technology in the assembly of large carbon fiber reinforced thermoplastic (CFRTP) parts [10,11,12]
Eloss is the loss modulus, which can be determined by the calculated nodal temperature and the temperature–loss modulus relationship obtained from a dynamic mechanical analysis (DMA) test
Summary
Lightweight materials can effectively reduce fuel consumption and exhaust emissions in the transportation domain, which is of great significance for environmental protection [1,2]. As a promising joining method for CFRTP, ultrasonic plastic welding (UPW) has the advantages of high efficiency, energy saving, easy to operate and convenient for in-situ monitoring [6,7,8,9]. Khmelev et al [14] modeled UPW from the perspective of wave propagation and calculated the distribution of input energy in the weld area. The authors have previously proposed a numerical method for the thermal-mechanical coupling analysis of nonlinear friction behavior and temperature characterization in ultrasonic welding of Al to Cu and Al to CFRTP [21,22]. The authors have previously proposed a numerical method for the thermal-mechanical coupling analysis of nonlinear friction behavior and temperature characterizat3ioonf 1i3n ultrasonic welding of Al to Cu and Al to CFRTP [21,22].
Sign-in/Register to view highlights & summary Sign-in/Register to access full text options 
Free) 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a call
