摩擦辅助超声波焊接塑料构件成热机理与应用

Thermal Mechanism Analysis and Application Research of Friction-assisted Ultrasonic Welding of Plastic Components

在超声波焊接基础上,结合旋转超声加工的特点,提出了摩擦辅助超声波焊接新方法,建立了左右拼接及上下固接焊接方式模型,推导出了热流密度计算公式。运用ANSYS软件热力耦合模块,建立了尼龙材质塑料件焊接熔化温度场模型,分析了在转速400r/min、轴向力10N和焊接振幅10μm的条件下,摩擦及超声作用的成热机理及可达温度,以摩擦作用1s所产生的温度(191℃)为启动热源,超声作用时间为0.5s所产生的温度为255℃,达到尼龙材质塑料件的熔化温度。进行单一摩擦热作用与摩擦辅助超声作用基础试验,得到了良好的焊接效果,验证了模拟分析的正确性,表面引入摩擦辅助可以显著提高塑料焊接熔化效率,有利于摆脱传统超声波焊接对振幅的依赖性,拓展超声波焊接的使用范围。

Based on the characteristics of ultrasonic ultrasonic welding combined with the characteristics of rotary ultrasonic machining,a new method of friction assisted ultrasonic welding was proposed.The model of left and right splicing and upper and lower fixed welding methods was established,and the calculation formula of heat flux was derived.Using the ANSYS software thermal coupling module,the welding melting temperature field model of nylon plastic parts was established,and the heating mechanism and the reaching temperature of friction and ultrasonic action at 400 r/min,axial force 10 N and welding amplitude 10μm were analyzed: friction for 1s the generated temperature (191℃) was the starting heat source,and the temperature generated by the ultrasonic action time of 0.5 s was 255℃,which reached the melting temperature of the nylon plastic parts.The basic test of single frictional heat and friction-assisted ultrasonication was carried out to obtain a good welding effect.The correctness of the simulation analysis was verified.The friction assisting energy on the surface could significantly improve the welding efficiency of plastic welding,which was beneficial to get rid of the amplitude dependence of traditional ultrasonic welding.