High temperature, short welding time, and low relative motion generate high bond quality in ultrasonic metal welding (USMW). Friction is considered to be the main heat source during USMW. Hence, a comprehensive and accurate understanding of friction heating has become particularly valuable for designing USMW processes and devices. However, stick, slip, and separation states may appear alternately in the welding zone between superimposed workpieces during USMW vibrations; hence, a strong nonlinear process is created. Furthermore, the structural dynamics and the heat transfer are highly coupled because material properties depend on temperature. In this research, we propose a fast and accurate numerical methodology to calculate the friction heating through a multiphysical approach integrating a nonlinear contact model, a nonlinear structural dynamics model, and a thermal model. The harmonic balance method and the finite element method are utilized to accelerate the simulation. Several experiments were performed with aluminum and copper workpieces under different clamping forces and vibration amplitudes to confirm the presented numerical method, resulting in a good match.
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June 2019
Research-Article
Nonlinear Dynamics of Friction Heating in Ultrasonic Welding
Zhiwei Liu,
Zhiwei Liu
Faculty of Vehicle Engineering and Mechanics,
Dalian, Liaoning 116024,
Dalian University of Technology
,Dalian, Liaoning 116024,
China
;Department of Mechanical Engineering,
Ann Arbor, MI 48105
e-mail: zhiweili@umich.edu
University of Michigan
,Ann Arbor, MI 48105
e-mail: zhiweili@umich.edu
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Yang Li,
Yang Li
Department of Mechanical Engineering,
Ann Arbor, MI 48105
e-mail: umliyang@umich.edu
University of Michigan
,Ann Arbor, MI 48105
e-mail: umliyang@umich.edu
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Yuefang Wang,
Yuefang Wang
Faculty of Vehicle Engineering and Mechanics,
Dalian, Liaoning 116024,
e-mail: yfwang@dlut.edu.cn
Dalian University of Technology
,Dalian, Liaoning 116024,
China
e-mail: yfwang@dlut.edu.cn
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Elijah Kannatey-Asibu, Jr.,
Elijah Kannatey-Asibu, Jr.
Department of Mechanical Engineering,
Ann Arbor, MI 48105
e-mail: asibu@umich.edu
University of Michigan
,Ann Arbor, MI 48105
e-mail: asibu@umich.edu
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Bogdan I. Epureanu
Bogdan I. Epureanu
1
Department of Mechanical Engineering,
Ann Arbor, MI 48105
e-mail: epureanu@umich.edu
University of Michigan
,Ann Arbor, MI 48105
e-mail: epureanu@umich.edu
1Corresponding author.
Search for other works by this author on:
Zhiwei Liu
Faculty of Vehicle Engineering and Mechanics,
Dalian, Liaoning 116024,
Dalian University of Technology
,Dalian, Liaoning 116024,
China
;Department of Mechanical Engineering,
Ann Arbor, MI 48105
e-mail: zhiweili@umich.edu
University of Michigan
,Ann Arbor, MI 48105
e-mail: zhiweili@umich.edu
Yang Li
Department of Mechanical Engineering,
Ann Arbor, MI 48105
e-mail: umliyang@umich.edu
University of Michigan
,Ann Arbor, MI 48105
e-mail: umliyang@umich.edu
Yuefang Wang
Faculty of Vehicle Engineering and Mechanics,
Dalian, Liaoning 116024,
e-mail: yfwang@dlut.edu.cn
Dalian University of Technology
,Dalian, Liaoning 116024,
China
e-mail: yfwang@dlut.edu.cn
Elijah Kannatey-Asibu, Jr.
Department of Mechanical Engineering,
Ann Arbor, MI 48105
e-mail: asibu@umich.edu
University of Michigan
,Ann Arbor, MI 48105
e-mail: asibu@umich.edu
Bogdan I. Epureanu
Department of Mechanical Engineering,
Ann Arbor, MI 48105
e-mail: epureanu@umich.edu
University of Michigan
,Ann Arbor, MI 48105
e-mail: epureanu@umich.edu
1Corresponding author.
Manuscript received November 30, 2018; final manuscript received April 3, 2019; published online April 19, 2019. Assoc. Editor: Wayne Cai.
J. Manuf. Sci. Eng. Jun 2019, 141(6): 061011 (10 pages)
Published Online: April 19, 2019
Article history
Received:
November 30, 2018
Revision Received:
April 3, 2019
Accepted:
April 4, 2019
Citation
Liu, Z., Li, Y., Wang, Y., Kannatey-Asibu, E., Jr., and Epureanu, B. I. (April 19, 2019). "Nonlinear Dynamics of Friction Heating in Ultrasonic Welding." ASME. J. Manuf. Sci. Eng. June 2019; 141(6): 061011. https://doi.org/10.1115/1.4043455
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