Suresh 2007
Suresh 2007
Abstract
   Use of engineering plastics in structural and non-structural applications is rapidly increasing. As the demand for plastics increases so does
the requirements for joining. Of the many techniques that are available for joining of thermoplastics, ultrasonic welding is one of the preferred
processes. Thermoplastic polymers are categorized according to their molecular structure as amorphous and semi-crystalline. Ultrasonic welding
of these two types of thermoplastics is expected to be quite different. As heating is confined to the interface area, quality of weld mainly depends
on temperature at the interface. So study on temperature distribution during welding is very important to predict the quality of weld. Viscoelastic
heating is most critical to ultrasonic welding of thermoplastics because it is the main mechanism by which heat is developed at the interface. Heat
developed due to viscoelastic heating depends on applied frequency, square of amplitude and loss modulus. In this study, modeling of temperature
distribution for various joint designs of thermoplastics as practised by industry is attempted and simulation is done in ANSYS. Model is validated
by measurement of temperature during welding.
© 2006 Elsevier B.V. All rights reserved.
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doi:10.1016/j.jmatprotec.2006.12.028
                                 K.S. Suresh et al. / Journal of Materials Processing Technology 186 (2007) 138–146                       139
Kenney [3] on engineering thermoplastics with crystalline struc-               The quality of weld depends on the heat affected zone
tures suggested a shear joint because it is self sealing, reduces           (HAZ) and temperature distribution for a given set of param-
heat loss and prevents oxidation in susceptible resins. The author          eters. The parameters include amplitude, frequency, material
also suggested an alternative to shear joint. This method involves          characteristics, weld time and joint configuration. Amorphous
molded-in-texturing of the welding surface opposite to an energy            thermoplastics are energy efficient and usually require low
director. The textured surface consists of peaks and valleys of             ultrasonic energy levels. They are characterized by a random
3–6 mm in size. During welding the textured surface produces                molecular arrangement and broad softening range. This allows
more compact melt and better heat transfer across the joint. A              the material to flow easily without premature solidification.
study by Chuah et al. [4] discussed the effects of the shape of             Semi-crystalline resins need higher ultrasonic levels because
the energy directors on far field ultrasonic welding. It was found          they have an orderly molecular structure. In the solid state the
that the energy directors with semicircular shape yielded high-             molecules absorb mechanical vibrations and very high amount
est welding efficiency followed by the rectangular and triangular           of energy is necessary to breakdown the crystalline structure so
shapes. A semicircular shaped energy director had a greater con-            that material melts and flows.
tact area than the other two energy directors and hence greater
welding efficiency.                                                         3. Objective
    A study was made by Benatar et al. [5] on high frequency
ultrasonic wave propagation and attenuation. Measurements                      From the literature review it is concluded that there is enough
were made in order to estimate the dynamic mechanical mod-                  scope to carry out research in mathematical modeling and eval-
uli of the polymers. The estimated moduli were entered into a               uation of temperature distribution for different joint designs in
lumped parameter model to predict heating rates and energy                  ultrasonic welding. Thus this work is taken up. The objective
dissipation. Benatar and Cheng [6] developed a model for                    of this work is to model the temperature distribution during
wave propagation in viscoelastic materials to predict vibration             ultrasonic welding for an amorphous (ABS) and semi-crystalline
amplitude experienced at the joint interface. This study indi-              (HDPE) thermoplastics for several possible joint designs using
cates that increasing the length of the samples to a half wave              software ANSYS and validate the model by measurement of
length can improve the far field welding of semi-crystalline                temperature. This will help understand the spread of HAZ in
polymers by maximizing the amplitude of vibration at the                    ultrasonic welding and quality of weld.
joint interface. Ultrasonic welding of oriented poly propylene
(OPP) using tie-layer materials has been examined by Tateishi               4. Mathematical analysis
et al. [7]. The thermal cycle at the joint interface was eval-
uated using high speed data acquisition system. The authors                      The governing differential equation to be solved is
found that the total time required for completion of the weld-                  ∂2 T    ∂2 T        ∂T
ing process decreases when applied pressure and amplitude are               k        + k 2 + Q − ρc    =0
                                                                                ∂x 2    ∂y          ∂t
increased.
    Aliosio et al. [8] investigated the ultrasonic welding of poly-         where ρ is density (kg/m3 ), c specific heat capacity (J/kg K), Q
carbonate, ABS and Noryl—using rectangular energy directors.                volumetric heat generation rate (W/m3 ) and k is isotropic thermal
They modeled the viscoelastic heating of the energy directors               conductivity (W/m K).
assuming adiabatic heating, and used elastic analysis to estimate              The standard sample shown in Fig. 1 (developed by Nedu-
the strain amplitude within parts.                                          landse Philips) [5] was used for analysis and experimental work.
   Applying suitable initial and boundary conditions this equa-                    6 mm from the interface. So the intensity of energy at the inter-
tion is solved using ANSYS software.                                               face is reduced because of attenuation (result of true absorption
                                                                                   and scattering) of waves.
• Initial condition
                                                                                   6. ANSYS analysis
   T (x, y, 0) = T0 = room temperature
                                                                                       A standardized sample which was developed by Nedulandse
                                                                                   Philips was used for analysis. Standard specimen with different
• Boundary conditions
                                                                                   joint designs (triangular, semicircular, and shear) is modeled.
      Q(0, y, t) = Qconvection ,        0 ≤ y ≤ 30, 0 ≤ t ≤ tweld time ,           For modeling, axy-symmetry concept is used because the speci-
                                                                                   men is symmetric about the Z axis. For this full transient analysis
   Q(29, y, t) = Qconvection ,          0 ≤ y ≤ 30, 0 ≤ t ≤ tweld time             the properties considered are coefficient of thermal conductiv-
                                                                                   ity (k) specific heat (c) and density (ρ). The properties of these
   where Qconvection is the heat lost due to convection to the sur-
                                                                                   plastics are listed in Table 1. The type of element used for analy-
   roundings from lateral surfaces of area A with overall heat
                                                                                   sis is PLANE 55 (solid-Quad 4 node). In meshing, a finer mesh
   transfer coefficient (h) of 0.1 J/m2 ◦ C.
                                                                                   (smart size of 2) size than default value was used. The governing
                                                                                   equation was solved by applying the initial and boundary con-
   Q(x, 0) = Qvisco , 0 ≤ x ≤ 29, where Qvisco is the viscoelastic                 ditions as mentioned earlier. The preprocessor for semicircular
heating (heat flux) in W/m2 .                                                      joint design (ABS-near field) is shown in Fig. 2 as an example.
   The following assumptions were made for calculating vis-                        Using various options available in postprocessor the required
coelastic energy dissipated.                                                       outputs are obtained.
(1) The triangular energy director and semicircular energy                         7. Experimental procedure
    director can be approximated as a rectangular energy direc-
    tor of equal cross-sectional area.                                                 All the welding was carried out using a conventional ultrasonic plastic
(2) Amplitude of vibration is taken by the top part and the energy                 machine (1500 W, 20 kHz) manufactured by M/s National Indosonic. Horn made
                                                                                   of aluminum–titanium alloy was used for this study. The horn used for welding
    director.                                                                      had diameters of 28 and 30 mm for near field and far field welding, respectively.
(3) The loss modulus is not a function of temperature.                                 The materials evaluated are
    A viscoelastic material that is subjected to a sinusoidal strain                  A standardized sample (which was developed by Nedulandse Philips) was
dissipates some energy through intermolecular friction. The stor-                  used in all the experiments in near field and far field welding. The specimen
age modulus for a viscoelastic material is the in-phase modulus                    with different energy directors were made by injection molding. A ZWICK
and it is a measure of the ability to store energy. The loss modulus               1484 tensile tester was used to measure the strengths of the welded joints. Test
                                                                                   procedures according to ASTM standard D638-97 (Standard Test Method for
is out of phase modulus and it is a measure of energy dissipated.
                                                                                   Tensile properties of plastics) were used. The deformation rate used in the testing
The average energy dissipated per unit time is given by                            was 50 mm/min.
        ωε20 E
Q=               J/m3 s                                                  (1)       8. Data acquisition system
           2
where Q is the average power dissipated, ω = 2πf, f the applied                       The temperatures at different points of the specimen were
frequency, ε0 the maximum strain and E is the loss modulus.                      monitored in real time using a high speed data acquisition
The peak strain ε0 during welding was calculated based on an                       system. The data acquisition system includes sensors (ther-
elastic analysis.                                                                  mocouple), terminal block, DAQ card and analyzing software.
    Viscoelastic heating is most critical to ultrasonic welding of                 The block diagram of data acquisition system is shown in
thermoplastics because without sufficient heating the interface                    Fig. 3(a). All the temperatures were measured using SWG 36
cannot melt and fuse to form the joint. In the case of near field                  Alumal–Cromal (type K) thermocouples positioned at different
welding horn is very close to the interface. But in the case of far                points on the specimen as shown in figure no. 1. The thermo-
field welding horn is located at a distance which is more than                     couple signal was fed into a terminal block (TBX 68 T) and
Table 1
Properties of the thermoplastics used
Material       Coefficient of thermal            Density (ρ)              Specific heat (c)         Melting              Loss modulus             Maximum tensile
               conductivity (k) (W/m ◦ C)        (kg/m3 )                 (J/kg ◦ C)                point (◦ C)          (E ) (GPa)             strength (MPa)
Fig. 3. (a) Process data acquisition system and (b) experimental setup for temperature measurement.
142                                     K.S. Suresh et al. / Journal of Materials Processing Technology 186 (2007) 138–146
Fig. 4. (a) Temperature distribution (in ◦ C) (from ANSYS analysis) and (b)
temperature distribution (experimental results). Material, ABS; type of joint,   Fig. 6. (a) Temperature distribution (in ◦ C) (from ANSYS analysis) and (b) tem-
semicircular energy director; field, near field; frequency, 20 kHz; amplitude,   perature distribution (experimental results). Material, ABS; type of joint, shear
60 m. Welding conditions: weld pressure, 3 bar; weld time, 0.3 s; hold time,    joint; field, near field; frequency, 20 kHz; amplitude, 60 m. Welding conditions:
1.0 s.                                                                           weld pressure, 3 bar; weld time, 0.3 s; hold time, 1.0 s.
                                        K.S. Suresh et al. / Journal of Materials Processing Technology 186 (2007) 138–146                                        143
                                                                                     Fig. 9. (a) Temperature distribution (in ◦ C) (from ANSYS analysis) and (b) tem-
Fig. 7. (a) Temperature distribution (in ◦ C) (from ANSYS analysis) and (b)
                                                                                     perature distribution (experimental results). Material, ABS; type of joint, shear
temperature distribution (experimental results). Material, ABS; type of joint,
                                                                                     joint; field, far field; frequency, 20 kHz; amplitude, 60 m. Welding conditions:
semicircular energy director; field, far field; frequency, 20 kHz; amplitude,
                                                                                     weld pressure, 3 bar; weld time, 0.8 s; hold time, 1.0 s.
60 m. Welding conditions: weld pressure, 3 bar; weld time, 0.8 s; hold time,
1.0 s.
                                                                                     tion is 60.942 ◦ C and in experiment it is 56 ◦ C. The percentage
                                                                                     error in this case is 8.75. The temperature at the interface for
                                                                                     triangular energy director is more than with semicircular energy
                                                                                     director. The triangular energy director concentrates more vis-
                                                                                     coelastic heat developed towards the interface. So initializing of
                                                                                     melting will start quickly for small weld time.
                                                                                         The temperature variations for shear joints are shown in
                                                                                     Fig. 6(a) and (b). Maximum interface temperature in simulation
                                                                                     and experimental analysis are 68.695 and 68 ◦ C, respectively.
                                                                                     Shear joint is a closed joint so that heat loss due to convection
                                                                                     is less. This may be the reason for higher interface temperature
                                                                                     than that in energy director joints.
                                                                                         The temperature distributions for ABS in far field configura-
                                                                                     tion are shown in Figs. 7(a), 8(a) and 9(a) and 7(b), 8(b) and 9(b).
                                                                                     In far field welding, the intensity of ultrasonic waves would
                                                                                     decrease inversely with the distance from the energy source. This
                                                                                     results from two basic causes-scattering and true absorption,
                                                                                     which are combined in the term attenuation. The change in inten-
                                                                                     sity of ultrasonic wave with distance as a result of attenuation
                                                                                     can be represented as shown in Eq. (2):
                                                                                                      I0
                                                                                     2αz = 20 log        dB                                                       (2)
                                                                                                      I
                                                                                     where I0 and I are intensity at the beginning and the end, respec-
Fig. 8. (a) Temperature distribution (in ◦ C) (from ANSYS analysis) and (b)
                                                                                     tively, for a section of length z with attenuation coefficient α.
temperature distribution (experimental results). Material, ABS; type of joint,
triangular energy director; field, far field; frequency, 20 kHz; amplitude, 60 m.   The attenuation coefficient α (in dB/m) for plastics at 20 kHz is
Welding conditions: weld pressure, 3 bar; weld time, 0.8 s; hold time, 1.0 s.        in the range of 10–100 [9]. For this study α is taken as 50 dB/m.
144                                      K.S. Suresh et al. / Journal of Materials Processing Technology 186 (2007) 138–146
Fig. 10. (a) Temperature distribution (in ◦ C) (from ANSYS analysis) and (b)
temperature distribution (experimental results). Material, HDPE; type of joint,
semicircular energy director; field, near field; frequency, 20 kHz; amplitude,
60 m. Welding conditions: weld pressure, 3 bar; weld time, 0.8 s; hold time,     Fig. 11. (a) Temperature distribution (in ◦ C) (from ANSYS analysis) and (b)
1.0 s.                                                                            temperature distribution (experimental results). Material, HDPE; type of joint,
                                                                                  triangular energy director; field, near field; frequency, 20 kHz; amplitude, 60 m.
                                                                                  Welding conditions: weld pressure, 3 bar; weld time, 0.8 s; hold time, 1.0 s.
Table 4
Comparison of simulated and experimental results (interface temperature)
(HDPE-near field)
Type of joint                    Simulated             Experimental
                                 results (◦ C)         results (◦ C)
Triangular energy director        82.357               72.5                   Fig. 12. (a) Temperature distribution (in ◦ C) (from ANSYS analysis) and (b)
Semicircular energy director      70.758               70                     temperature distribution (experimental results). Material, HDFE; type of joint,
Shear joint                      104.856               78                     shear joint; field, near field; frequency, 20 kHz; amplitude, 60 m. Welding
                                                                              conditions: weld pressure, 3 bar; weld time, 0.8 s; hold time, 1.0 s.
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Acknowledgements