Mechanical Analysis of Ultrasonic Bonding for Rapid Prototyping

2002 ◽  
Vol 124 (2) ◽  
pp. 426-434 ◽  
Author(s):  
Yuan Gao ◽  
Charalabos Doumanidis
Keyword(s):  
Rapid Prototyping ◽  
Substrate Surface ◽  
Computational Simulation ◽  
Welding Process ◽  
Mechanical Analysis ◽  
Metal Foil ◽  
Stress Concentrations ◽  
Ultrasonic Probe ◽  
Ultrasonic Bonding ◽  
Foil Substrate

Ultrasonic bonding of thin foils has been recently introduced to rapid prototyping of complex-shaped and/or internally structured layered parts. This article provides the mechanical analysis of an elementary ultrasonic spot welding process of a metal foil on a previously deposited substrate. A 2-D, quasi-static/dynamic, elasto-plastic numerical model of the stress/strain field is developed by finite element analysis. Its frictional boundary conditions at the foil/substrate interface are described via a simpler plain stress, static analytical formulation, and identified experimentally by strain measurements on the substrate surface, adjacently to the ultrasonic probe. The calibrated computational simulation is validated in the laboratory and applied in studying the elastic stress concentrations, plastic deformation initiation and propagation patterns, the slippage at the interface surface and the dynamic effects of ultrasonic loading on the bonding process. This mechanical model is suitable for analysis of multi-joint ultrasonic rapid prototyping and its applications in fabrication of multi-material, functional internal structures with embedded components.

scholarly journals Structure Analysis and Design of Automobile plastic clutch pump body based on friction welding

2020 ◽  
Vol 316 ◽  
pp. 02001
Author(s):  
Jing Sheng ◽  
Aamir Sohail ◽  
Mengguang Wang ◽  
Zhimin Wang
Keyword(s):  
High Temperature ◽  
Structural Design ◽  
Friction Welding ◽  
Room Temperature ◽  
Welding Process ◽  
Structure Type ◽  
Mechanical Analysis ◽  
Analysis And Design ◽  
Technical Requirements ◽  
Design Requirements

In order to realize the need for lightweight automobiles through replacing steel with plastics, the research and development of the plastic clutch pump body based on the friction welding was carried out. For the clutch pump body connected by friction welding process between the upper pump body and the lower pump body, the technical requirements of pressure 14 MPa and durability (high temperature 7.0 × 104 times, room temperature 7.0 × 105) are required. The structure type of the upper and lower pump bodies of the end face welding type was proposed. Through the static analysis of the pump body and weld and the mechanical analysis under the working condition, the structure of the clutch pump body (upper and lower pump body) was determined. According to the established welding process, the pressure of the clutch pump body is more than 15 MPa, and the number of high-temperature durable circulation and the number of room temperature durable circulation also reached 7.2×104 and 7.3×105 times respectively. The results show that the structural design of a clutch pump body meets the design requirements.

Thermomechanical Model of Spot Welding for Calculating Residual Stresses

2003 ◽  
Author(s):  
Lijun Xu ◽  
Jamil A. Khan
Keyword(s):  
Residual Stresses ◽  
Heat Generation ◽  
Spot Welding ◽  
Welding Process ◽  
Mechanical Analysis ◽  
Temperature Dependent ◽  
Thermomechanical Model ◽  
Faying Surface ◽  
Proposed Model ◽  
Electrode Interface

A comprehensive axisymmetric model of the coupled thermal-electrical-mechanical analysis predicting weld nugget development and residual stresses for the resistance spot welding process of Al-alloys is developed. The model estimates the heat generation at the faying surface, the workpiece-electrode interface, and the Joule heating of the workpiece and electrode. The phase change due to melting in the weld pool is considered. The contact area and its pressure distribution at both the faying surface and the electrode-workpiece interface are determined from a coupled thermal-mechanical model using a finite element method. The knowledge of the interface pressure provides accurate prediction of the interfacial heat generation. For the numerical model, temperature dependent thermal, electrical and mechanical properties are used. The proposed model can successfidly calculate the nugget diameter and thickness, and predict the residual stresses and the elastic-plastic deformation history. The calculated nugget shape and the deformation of sheets based on the model are compared with the experimental data. The computed residual stresses approach the distribution of experimental measurement of the residual stress.

Experimental and numerical simulation of thermomechanical phenomena during a TIG welding process

2004 ◽  
Vol 120 ◽  
pp. 697-704
Author(s):  
L. Depradeux ◽  
J.-F. Jullien
Keyword(s):  
Numerical Simulation ◽  
Numerical Models ◽  
Welding Process ◽  
Central Zone ◽  
Mechanical Analysis ◽  
Tig Welding ◽  
General Ability ◽  
Reduced Dimensions ◽  
Simple Geometry ◽  
A Tig Welding

In this study, a parallel experimental and numerical simulation of phenomena that take place in the Heat Affected Zone during TIG welding on 316L stainless steel is presented. The aim of this study is to predict by numerical simulation residual stresses and distortions generated by the welding process. For the experiment, a very simple geometry with reduced dimensions is considered: the specimens are disks, made of 316L. The discs are heated in the central zone in order to reproduce thermo-mechanical cycles that take place in the HAZ during a TIG welding process. During and after thermal cycle, a large quantity of measurement is provided, and allows to compare the results of different numerical models used in the simulations. The comparative thermal and mechanical analysis allows to assess the general ability of the numerical models to describe the structural behavior. The importance of the heat input rate and material characteristics is also investigated.

Computational simulation of the relaxation of local stresses due to foreign object damage under cyclic loading

2010 ◽  
Vol 224 (2) ◽  
pp. 41-50 ◽  
Author(s):  
T Davis ◽  
J Ding ◽  
W Sun ◽  
S B Leen
Keyword(s):  
Stress Relaxation ◽  
Kinematic Hardening ◽  
Computational Simulation ◽  
Fatigue Loading ◽  
Cyclic Fatigue ◽  
Foreign Object ◽  
Stress Concentrations ◽  
Foreign Object Damage ◽  
Stress Ratios ◽  
The Impact

In this study, the phenomenon of residual stress relaxation from foreign object damage (FOD) is numerically simulated using a hybrid explicit—implicit finite-element method. The effects of cycle fatigue loadings on stress relaxation were studied. FOD is first simulated by firing a 3mm cube impacting onto a plate made of titanium alloy Ti-6Al-4V at 200m/s. The FOD impact produces two distinct stress concentrations: one is compressive directly beneath the impact site; the other is tensile around the outer edge of the impact. The plate was then assumed to be subjected to a cyclic fatigue loading. The stress relaxation was investigated under a range of stress ratios and maximum applied stresses. Two different material models were considered for the simulations, namely an elastic—perfectly plastic model and a non-linear kinematic hardening model.

Ultrasonic Rapid Manufacturing: Implementation and Thermo-Mechanical Analysis

2002 ◽  
Author(s):  
Shailendra Yadav ◽  
Charalabos Doumanidis
Keyword(s):  
Temperature Effects ◽  
Welding Process ◽  
Mechanical Analysis ◽  
Ultrasonic Welding ◽  
Solid Metal ◽  
Rapid Manufacturing ◽  
Mechanical Process ◽  
Ultrasonic Metal Welding ◽  
Metal Parts ◽  
Metal Welding

This paper addresses a novel non-thermal Ultrasonic Rapid Manufacturing (URM), for layered parts based on Ultrasonic Metal Welding (USW). Its laboratory implementation, automation and integration are described first. The thermo-mechanical process aspects (i.e. heat generation and resulting temperature effects) during each cycle of ultrasonic welding are then studied. The technical advantages of ultrasonic welding process, including fabrication of dense, full-strength functional solid metal parts, multi-material composites, and active parts with embedded intelligent components and electronic, mechatronic, optic and fluidic structures, are examined.

Numerical Simulations of Friction Stir Welding Process and Subsequent Post Weld Cold Rolling Process

2009 ◽  
Vol 419-420 ◽  
pp. 433-436 ◽  
Author(s):  
Yu Jie Sun ◽  
Yong Zang ◽  
Qing Yu Shi
Keyword(s):  
Residual Stress ◽  
Friction Stir Welding ◽  
Three Dimensional ◽  
Welding Process ◽  
Rolling Process ◽  
Mechanical Analysis ◽  
Fusion Welding ◽  
Work Piece ◽  
Friction Stir ◽  
Longitudinal Residual Stress

A sequential coupled three-dimensional thermo-mechanical analysis was conducted first to simulate friction stir welding (FSW) of aluminum alloy. In thermal analysis, the model included adaptive heat source, contact heat transfer both between work piece and clamps and between work piece and backing board etc; in the mechanical analysis, the model involved contact interaction both between work piece and clamps and between work piece and backing board, mechanical load of tool etc. The simulation results indicate that the longitudinal residual stress is unsymmetrical about weld centerline; the magnitude of longitudinal residual stress for FSW process is lower than that for fusion welding process. Based on simulated results of FSW process, a three-dimensional elastic-plastic analysis was then carried out to simulate rolling process, the simulation result show that rolling process not only causes a marked reduction in the longitudinal tensile residual but also reverse the sign of the longitudinal residual stress.

Prediction of weld-induced distortion of large structure using equivalent load technique

2016 ◽  
Vol 232 (3) ◽  
pp. 499-512 ◽  
Author(s):  
Arpan Kumar Mondal ◽  
Anche Lohit ◽  
Pankaj Biswas ◽  
Swarup Bag ◽  
Manas Das
Keyword(s):  
Welding Process ◽  
Residual Deformation ◽  
Computation Time ◽  
Mechanical Analysis ◽  
Angular Distortion ◽  
Computational Time ◽  
Large Structure ◽  
Welded Structure ◽  
Weld Structure ◽  
Equivalent Load

Angular distortion in fusion welded joints is an alarming issue which affects the stability and life of the welded structures, occurs due to the changes in the temperature gradient during the welding process. This degrades the dimensional quality of a large structure during assembly which leads to rework the products and hence decreases the productivity. Predicting the weld-induced residual deformation before the production saves the valuable time and resources for rework. The conventional coupled transient, nonlinear, elasto-plastic thermo-mechanical analysis involves huge computational time. Computing a weld sample of small size with single pass itself takes several hours, which will be a huge amount of time in case of large structures consisting of several welding passes; thus, there is a real need of an efficient alternative technique to predict the post-weld distortions. In this work, an attempt has been made to determine the deformation in a submerged arc welded structure using equivalent load technique which reduces the total analysis time by one-third of the conventional techniques in case of a small weld structure. In this proposed method, the transient nonlinear elasto-plastic structural analysis part which is the major time-consuming part of analysis has been almost eliminated. So, this method can effectively use to predict the weld-induced distortion of very large structure with a computation time almost equal to the time required for transient thermal analysis of a small weld structure only. It is not feasible to analyze such a large welded structure with conventional coupled transient, elasto-plastic, nonlinear thermo-mechanical analysis. The predicted results of distortions have been validated with the experimental as well as published results and good agreements have been found.

An Improved Numerical Modeling for Resistance Spot Welding Process and Its Experimental Verification

1998 ◽  
Vol 120 (2) ◽  
pp. 246-251 ◽  
Author(s):  
O. P. Gupta ◽  
Amitava De
Keyword(s):  
Resistance Spot Welding ◽  
Spot Welding ◽  
Hsla Steel ◽  
Low Carbon Steel ◽  
Welding Process ◽  
Current Density Distribution ◽  
Mechanical Analysis ◽  
Electrode System ◽  
Low Carbon ◽  
Resistance Spot

A numerical model of resistance spot welding with spherical tip electrode is developed to incorporate the electro-thermal aspect as well as thermo-elasto-plastic behaviour inherent in this process. The electro-thermal aspect includes the Joule’s resistive heating along the contact surfaces and within the sheet-electrode system due to nonuniform current density distribution in the sheet-electrode. The elasto-plastic deformation of the sheet-electrode interface at higher temperature is included in the thermo-mechanical analysis. The interdependence of those two analyses has been taken care of The model is used to simulate the spot welding in low-carbon steel sheets of 1 mm and 2 mm thickness and HSLA steel sheet of 1 mm thickness. The results are compared with experimental data obtained as a part of this work and also with literature data. The comparison has shown a good agreement in all the cases. The results are later used to draw the thermal cycle curves at different location along the faying surface.

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