Simulation of temperature and weld growth mechanism in ultrasonic welding of carbon fiber reinforced polyamide 66 composite: Employing the high frequency real-time horn vibration
Ultrasonic welding (UW) of carbon fiber reinforced polyamide 66 (CF/PA 66) composite is a very promising process for assembly of automobile component. Simulation of the temperature distribution and weld growth in UW process remains a difficulty issue. In this study, a high frequency sensor is equipp...
| Main Authors: | , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
Elsevier
2023-11-01
|
| Series: | Journal of Materials Research and Technology |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785423028363 |
| _version_ | 1797301482325803008 |
|---|---|
| author | Xinrong Tan Qian Zhi Jinming Ma Yuhua Chen Yongbing Li |
| author_facet | Xinrong Tan Qian Zhi Jinming Ma Yuhua Chen Yongbing Li |
| author_sort | Xinrong Tan |
| collection | DOAJ |
| description | Ultrasonic welding (UW) of carbon fiber reinforced polyamide 66 (CF/PA 66) composite is a very promising process for assembly of automobile component. Simulation of the temperature distribution and weld growth in UW process remains a difficulty issue. In this study, a high frequency sensor is equipped in the welder to collect the real-time horn vibration during UW. Then the real-time horn vibration is applied on tip of the horn and integrated into the finite element model in Abaqus. The simulation results are validated with experimental tests of temperature and weld evolution in UW of CF/PA 66. Results showed the ultrasonically welded CF/PA 66 joint made with a weld time of 2.7 s consisted of five distinct stages and the characteristics in stage 3 determined the quality of the weld. An index Q based on the amplitude and duration of T3 was proposed to evaluate the joint quality. The accuracy of Q was also verified through extensive experiments. |
| first_indexed | 2024-03-07T23:23:13Z |
| format | Article |
| id | doaj.art-c708d4a7c4fb462898d31615200903f1 |
| institution | Directory Open Access Journal |
| issn | 2238-7854 |
| language | English |
| last_indexed | 2024-03-07T23:23:13Z |
| publishDate | 2023-11-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj.art-c708d4a7c4fb462898d31615200903f12024-02-21T05:27:42ZengElsevierJournal of Materials Research and Technology2238-78542023-11-012755595571Simulation of temperature and weld growth mechanism in ultrasonic welding of carbon fiber reinforced polyamide 66 composite: Employing the high frequency real-time horn vibrationXinrong Tan0Qian Zhi1Jinming Ma2Yuhua Chen3Yongbing Li4Hunan Engineering Research Center of Forming Technology and Damage Resistance Evaluation for High Efficiency Light Alloy Components, Hunan University of Science and Technology, Xiangtan, 411201, ChinaHunan Engineering Research Center of Forming Technology and Damage Resistance Evaluation for High Efficiency Light Alloy Components, Hunan University of Science and Technology, Xiangtan, 411201, China; Jiangxi Key Laboratory of Forming and Joining Technology for Aerospace Components, Nanchang Hangkong University, Nanchang, 330063, China; Shanghai Key Laboratory of Digital Manufacture for Thin-walled Structure, Shanghai Jiao Tong University, Shanghai, 200240, China; Corresponding author. Hunan Engineering Research Center of Forming Technology and Damage Resistance Evaluation for High Efficiency Light Alloy Components, Hunan University of Science and Technology, Xiangtan, 411201, China.Hunan Engineering Research Center of Forming Technology and Damage Resistance Evaluation for High Efficiency Light Alloy Components, Hunan University of Science and Technology, Xiangtan, 411201, ChinaJiangxi Key Laboratory of Forming and Joining Technology for Aerospace Components, Nanchang Hangkong University, Nanchang, 330063, China; Corresponding author.Shanghai Key Laboratory of Digital Manufacture for Thin-walled Structure, Shanghai Jiao Tong University, Shanghai, 200240, ChinaUltrasonic welding (UW) of carbon fiber reinforced polyamide 66 (CF/PA 66) composite is a very promising process for assembly of automobile component. Simulation of the temperature distribution and weld growth in UW process remains a difficulty issue. In this study, a high frequency sensor is equipped in the welder to collect the real-time horn vibration during UW. Then the real-time horn vibration is applied on tip of the horn and integrated into the finite element model in Abaqus. The simulation results are validated with experimental tests of temperature and weld evolution in UW of CF/PA 66. Results showed the ultrasonically welded CF/PA 66 joint made with a weld time of 2.7 s consisted of five distinct stages and the characteristics in stage 3 determined the quality of the weld. An index Q based on the amplitude and duration of T3 was proposed to evaluate the joint quality. The accuracy of Q was also verified through extensive experiments.http://www.sciencedirect.com/science/article/pii/S2238785423028363Ultrasonic weldingCarbon fiber reinforced polyamide 66SimulationTemperature evolutionWeld growth |
| spellingShingle | Xinrong Tan Qian Zhi Jinming Ma Yuhua Chen Yongbing Li Simulation of temperature and weld growth mechanism in ultrasonic welding of carbon fiber reinforced polyamide 66 composite: Employing the high frequency real-time horn vibration Journal of Materials Research and Technology Ultrasonic welding Carbon fiber reinforced polyamide 66 Simulation Temperature evolution Weld growth |
| title | Simulation of temperature and weld growth mechanism in ultrasonic welding of carbon fiber reinforced polyamide 66 composite: Employing the high frequency real-time horn vibration |
| title_full | Simulation of temperature and weld growth mechanism in ultrasonic welding of carbon fiber reinforced polyamide 66 composite: Employing the high frequency real-time horn vibration |
| title_fullStr | Simulation of temperature and weld growth mechanism in ultrasonic welding of carbon fiber reinforced polyamide 66 composite: Employing the high frequency real-time horn vibration |
| title_full_unstemmed | Simulation of temperature and weld growth mechanism in ultrasonic welding of carbon fiber reinforced polyamide 66 composite: Employing the high frequency real-time horn vibration |
| title_short | Simulation of temperature and weld growth mechanism in ultrasonic welding of carbon fiber reinforced polyamide 66 composite: Employing the high frequency real-time horn vibration |
| title_sort | simulation of temperature and weld growth mechanism in ultrasonic welding of carbon fiber reinforced polyamide 66 composite employing the high frequency real time horn vibration |
| topic | Ultrasonic welding Carbon fiber reinforced polyamide 66 Simulation Temperature evolution Weld growth |
| url | http://www.sciencedirect.com/science/article/pii/S2238785423028363 |
| work_keys_str_mv | AT xinrongtan simulationoftemperatureandweldgrowthmechanisminultrasonicweldingofcarbonfiberreinforcedpolyamide66compositeemployingthehighfrequencyrealtimehornvibration AT qianzhi simulationoftemperatureandweldgrowthmechanisminultrasonicweldingofcarbonfiberreinforcedpolyamide66compositeemployingthehighfrequencyrealtimehornvibration AT jinmingma simulationoftemperatureandweldgrowthmechanisminultrasonicweldingofcarbonfiberreinforcedpolyamide66compositeemployingthehighfrequencyrealtimehornvibration AT yuhuachen simulationoftemperatureandweldgrowthmechanisminultrasonicweldingofcarbonfiberreinforcedpolyamide66compositeemployingthehighfrequencyrealtimehornvibration AT yongbingli simulationoftemperatureandweldgrowthmechanisminultrasonicweldingofcarbonfiberreinforcedpolyamide66compositeemployingthehighfrequencyrealtimehornvibration |