Abstract
The uniformity of amplitude distribution and amplitude gain are two main factors affecting the performance of ultrasonic welding vibration system. In order to improve the uniformity of amplitude distribution and amplitude gain of welding surface to enhance the performance of the vibration system, a new design method of a large-scale three-dimensional ultrasonic plastic welding vibration system based on a quasi-periodic phononic crystal structure is proposed. In this method, the composite horn combined with a conical section and a cylindrical section can effectively improve the output amplitude gain of the welding surface. In addition, the method forms a quasi-periodic phononic crystal structure by slotting in a large-scale three-dimensional tool head, and utilizes the band gap property of the structure to effectively suppress lateral vibration of the tool head and improve the amplitude distribution uniformity of the tool head’s welding surface. However, when the size of the tool head is relatively large, the quasi-periodic phononic crystal structure cannot suppress the lateral vibration very well. Therefore, the paper processes fan-shaped slopes on the output surface of the tool head which can further improve the uniformity of the amplitude distribution and amplitude gain. Finally, the simulation analysis and experiments show that the design method can optimize the large-scale three-dimensional ultrasonic plastic welding system, improve the uniformity of the vibration distribution and increase the output amplitude gain of the welding surface.
Highlights
Ultrasonic plastic welding technology has been widely used because of its advantages of fastness, flexibility, stable welding process, low cost, and environmental protection [1]
The research uses the band gap theory of quasi-periodic phononic crystal, combined with the fan-shaped slopes structure, composite horn, and COMSOL simulation to realize the optimal design of an ultrasonic welding vibration system, which can achieve the goal of improving the uniformity of displacement distribution of welding surface, shortening welding time, improving welding production efficiency, and increasing the system’s stability
From the comparison of the longitudinal relative displacement distribution of the welding surface in Figure 11, it can be seen that the longitudinal output displacement of the system based on the quasi-periodic phononic crystal structure is more uniform than that of the system without the quasi-periodic phononic crystal structure, which shows that the lateral vibration in X and Y directions is effectively controlled because of the influence of the quasi-periodic phononic crystal structure, which makes the longitudinal displacement of the tool head more uniform
Summary
Ultrasonic plastic welding technology has been widely used because of its advantages of fastness, flexibility, stable welding process, low cost, and environmental protection [1]. Lin et al applied the apparent elasticity to the rectangular tool head and studied the generation and suppression of coupled vibration [2]. Lin et al applied phononic crystal theory to the study of circular and rectangular tool heads. The paper proposes a large-scale three-dimensional ultrasonic plastic welding vibration system based on a quasi-periodic phononic crystal structure. The research uses the band gap theory of quasi-periodic phononic crystal, combined with the fan-shaped slopes structure, composite horn, and COMSOL simulation to realize the optimal design of an ultrasonic welding vibration system, which can achieve the goal of improving the uniformity of displacement distribution of welding surface, shortening welding time, improving welding production efficiency, and increasing the system’s stability. Theoretical Analysis of a Large-Scale Three-Dimensional Ultrasonic Plastic Welding
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