Ultrasonic welding process operations require multi-faceted integration, and good welding results are achieved after matching to the appropriate range. This article analyzes the four aspects of ultrasonic welding equipment erection, welding conditions, plastic product material, and energy output.
Ultrasonic horn and ultrasonic mould
It is generally believed that when ultrasonic welding, the product and the ultrasonic mold surface can be welded as long as the contact is accurate, which is incorrect. Ultrasonic welding uses the principle of frictional vibration to generate heat, which will produce the phenomenon of sound wave conduction.
If we only observe the degree of stability of the mold and ignore the integrated ultrasonic welding method, it must be wrong. Leads to the consequences of miscalculation. Therefore, it must first be confirmed that the operation mode of ultrasonic welding is to transmit ultrasonic waves, so that the vibration friction is converted into thermal energy and welded.
When the degree of stability of ultrasonic mold and horn, the height of the product cross-section, the thickness of the product, the depth, the microstructure of the plastic material, etc. all have an impact on the ultrasonic welding results. The force is uneven and the energy is unstable. It is bound to produce differences in the degree of welding of the product welding line.
In order to achieve higher precision ultrasonic welding, Mingyang ultrasonic welding adopts international famous ultrasonic welding equipment accessories to ensure the overall quality of ultrasonic welding.
This design will not let go of any details of the processing, The flange design, four horizontal screw adjustment, scale auxiliary adjustment all help to improve welding accuracy and design;
The base design is thickened and strengthened, and the high-precision CNC processing improves the flatness of the base mold installation position to ensure continuous stability of welding.
Ultrasonic welding conditions are not properly matched
The adjustment of ultrasonic work is the setting of the output power, pressure (dynamic pressure and static pressure), welding time, hardening time, delay time and other conditions of the machine.
Let’s take ultrasonic welding wire as an example, in the ultrasonic welding, if the pressure is too large, the cylinder drops and buffers too quickly, and it is easy to flatten the ultrasonic wire.
Although the ultrasonic line has been fused, it has sunk because the welding has been squeezed first, and the fusing effect has been lost. The strong breaking welding of plastic surfaces and surfaces is formed, rather than the guided welding of ultrasonic triangular points, which produces the illusion of good welding effect.
The material of plastic products is not properly matched
● The melting point of each plastic material is different, for example, the melting point of ABS plastic material is about 115 °C, the PC is about 145 °C or more, and the PE is about 85 °C.
●Because the melting point gap is larger, it is not easy to reach the melting point at the same time, and it is difficult to form an effective weld. The melting point gap between ABS and PE is too large, and ultrasonic welding is bound to be difficult.
●There is also a gap between ABS and PC materials, but the gap is within the acceptable range of ultrasonic welding, and ultrasonic welding machine can be carried out. However, in the case of the same ultrasonic power and the same energy expansion, the welding effect of the same plastic material is better
Ultrasonic welding conditions are not properly matched
The adjustment of ultrasonic work is the setting of the output power, pressure (dynamic pressure and static pressure), welding time, hardening time, delay time and other conditions of the machine.
Let’s take ultrasonic welding wire as an example, in the ultrasonic welding, if the pressure is too large, the cylinder drops and buffers too quickly, and it is easy to flatten the ultrasonic wire.
Although the ultrasonic line has been fused, it has sunk because the welding has been squeezed first, and the fusing effect has been lost. The strong breaking welding of plastic surfaces and surfaces is formed, rather than the guided welding of ultrasonic triangular points, which produces the illusion of good welding effect.
The material of plastic products is not properly matched
● The melting point of each plastic material is different, for example, the melting point of ABS plastic material is about 115 °C, the PC is about 145 °C or more, and the PE is about 85 °C.
●Because the melting point gap is larger, it is not easy to reach the melting point at the same time, and it is difficult to form an effective weld. The melting point gap between ABS and PE is too large, and ultrasonic welding is bound to be difficult.
●There is also a gap between ABS and PC materials, but the gap is within the acceptable range of ultrasonic welding, and ultrasonic welding machine can be carried out. However, in the case of the same ultrasonic power and the same energy expansion, the welding effect of the same plastic material is better
The output energy of ultrasonic welding equipment is insufficient
● When the existing machine is not enough to meet the higher energy welding demand, under the budget without increasing the cost, it can only be welded with existing equipment. At this time, it is usually used to separate welding, increase the ultrasonic output power or increase the welding time, pressure and so on.
●However, insufficient energy produces the phenomenon of unstable welding quality, and it is necessary to consider the power matching problem of accessories.
●Ultrasonic welding is not only affected by these problems, but also has new problems that need to be explored and tested for different welding needs.
●Mingyang ultrasonic has been committed to high-performance ultrasonic plastic welding equipment research and development, manufacturing, with nearly 20 years of professional manufacturing of ultrasonic equipment technology precipitation, is China’s earliest ultrasonic plastic welding equipment manufacturers.
●Ultrasonic plastic welder not only tests and do quality inspection of the equipment, but also customizes the installation and debugging service for plastic samples.
Post time: Jul-13-2022