滚花齿角度对铝合金超声焊接力学和热行为的影响。

Effects of knurl tooth angle on mechanical and thermal behaviors of aluminum ultrasonic welding.

机构信息

State Key Laboratory of Robotics and System, Harbin Institute of Technology, Harbin 150001, Heilongjiang Province, China.

出版信息

Ultrasonics. 2020 Dec;108:106207. doi: 10.1016/j.ultras.2020.106207. Epub 2020 Jun 11.

DOI:10.1016/j.ultras.2020.106207

PMID:32563717

Abstract

Ultrasonic welding (USW) has been receiving more and more attentions in material joining field due to its advantages of cleanness and high efficiency. The knurl tooth angle (KTA), as a key factor of horn knurl geometry (HKG), has significant influences on the contact and friction behavior of the joint formation. Although there have been some researches on the simulation of ultrasonic welding, the 3D finite element (FE) model considering the influence of KTA has not been reported. In this study, the FE models of different KTAs are established to reveal the effects of KTA on joint formation. The simulation result shows that the KTA greatly influences the process parameters of the USW after 0.025 s. The gaps of the faying interface and local stress concentration in the sonotrode-workpiece contact area, caused by KTAs less than 120°, are the main reasons for the strength reduction of the joint. The higher average equivalent plastic strain and temperature of the welding area, formed by KTAs greater than 130°, are turned out to be the main reasons for the formation of more bonds. The simulation has been verified by experiments, and the results provide guidance to improve the quality of the joint.

摘要

超声焊接（USW）由于其清洁和高效的优点，在材料连接领域越来越受到关注。滚花齿角（KTA）作为变幅杆滚花纹理（HKG）的关键因素，对接头形成的接触和摩擦行为有显著影响。尽管已经有一些关于超声焊接模拟的研究，但尚未报道考虑 KTA 影响的 3D 有限元（FE）模型。在这项研究中，建立了不同 KTA 的 FE 模型，以揭示 KTA 对接头形成的影响。模拟结果表明，KTA 在 0.025s 后对 USW 的工艺参数有很大影响。小于 120°的 KTA 会导致结合面间隙和变幅杆-工件接触区域局部应力集中，这是接头强度降低的主要原因。大于 130°的 KTA 会导致焊接区域的平均等效塑性应变和温度升高，这是形成更多结合的主要原因。模拟已通过实验验证，结果为提高接头质量提供了指导。