Ultrasonic welding of thermoplastic composites: a numerical analysis at the mesoscopic scale relating processing parameters, flow of polymer and quality of adhesion

摘要: Ultrasonic continuous welding of thermoplastic composite plates is a very promising process particular interest for the assembly aeronautics large parts. Its modeling and simulation however suffers from difficulty accounting different time scales that rule thermo-mechanical phenomena at level adhesion zone. This problem was addressed in our previous works led to an original tool presented Levy et al. (Eur J Mech A, Solids 30(4):501–509, 2011a). In this paper, adopted time-homogenized multiphysical flow mesoscopic scale energy directors first presented. Then, using numerical software 2D approach, extensive parametric study The allowing are confirmed be initial strain concentration director, formation flowing fold. influence following parameters finally investigated: amplitude vibrations, holding force sonotrode, thickness plates, radius curvature tip angle director. Process efficiency weld quality evaluated through simple indicators such as equivalent stiffness analysis, healing degree risk porosity entrapment. present study, carried scale, provides better understanding complex interactions between physical enables draw important technological conclusions design directors.