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Ultrasonic welding strength analysis and problem solving method

Generally, the smaller the volume of ultrasonic welding products and the higher the material density, heat resistance, etc., the higher the requirements for ultrasonic welding strength. The following will continue to introduce the conditions and solutions that occur when the welding strength is adjusted.

Situation 1:
The workpiece cannot be aligned after welding.

Reason 1:
The parts are not aligned when they are mated.

Solution:
1. Increase ribs between the two pieces of work.
2. Design fixtures or make positioning systems for guidance.

Reason 2:
Improper support of the bottom mold.

Solution:
1. Redesign the appropriate support fixtures and raise the bottom mold where necessary.
2. If the bakelite is inclined, add a hard bracket.

Reason 3:
The side wall is curved.

Solution:
1. The side wall of the workpiece is reinforced.
2. If the bakelite is inclined, add a hard bracket.

Reason 4:
Poor weld line design.

Solution:
Redesign the correct weld line.

Reason 5:
The workpiece tolerance is too large.

Solution:
1. The side wall of the workpiece is reinforced.
2. If the bakelite is inclined, add a hard bracket.

Situation 2:
During welding, internal parts were damaged.

Reason 1:
The amplitude is too large.

Solution:
Reduce the amplitude.

Reason 2:
The welding time is too long.

Solution:
1. Increase the amplitude or pressure and shorten the welding time.
2. Adjust the buffer pressure.

Reason 3:
The workpiece absorbs too much energy.

Solution:
1. Reduce the amplitude.
2. Reduce stress.
3. Shorten the welding time.
4. Use an energy controller.

Reason 4:
The parts are not properly matched, and the distance between the joint surfaces is too close.

Solution:
1. Make sure that the internal parts are appropriately matched to move the internal parts, avoiding the stress concentration area or the deformed pressing place.
2. Design fixtures to offset internal stress.