Journal of Jilin University(Engineering and Technology Edition) ›› 2025, Vol. 55 ›› Issue (8): 2548-2554.doi: 10.13229/j.cnki.jdxbgxb.20231176

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Dynamic friction action and ultrasonic softening during high-power ultrasonic welding process of pure copper

Huan LI(),Qian-xi LIU,Chang-xin ZHANG,Jian ZHANG   

  1. School of Mechanical Engineering，Yangtze University，Jingzhou 434023，China
  • Received:2023-10-30 Online:2025-08-01 Published:2025-11-14

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Abstract:

Based on the experimental results of interfacial temperature and sonotrode displacement， the finite element method was employed to investigate the friction and material softening process in pure copper ultrasonic welding， and the distribution of the temperature fields and plastic strain during the welding process were also analyzed. The results show that the established model can better simulate the dynamic friction coefficient and ultrasonic softening variation processes during welding. The average friction coefficient of the workpiece contact surface increased rapidly in the early stages of welding， and then decreased sharply， and presented smooth fluctuations after welding time of 0.2 s. The ultrasonic softening coefficlent of copper increased sharply in the early stages of welding， then slowly increased， and began to increase significantly when the welding time was 0.3 s. Ultrasonic softening is the main physical mechanism of materials plastic deformation.

Key words: materials synthesis and processing technology, ultrasonic welding, finite element simulation, friction coefficient, ultrasonic softening

CLC Number: 

  • TG456.9

Fig.1

High-power ultrasonic metal welding machine"

Fig.2

Schematic diagram of thermocouple temperature measurement"

Fig.3

Finite element model"

Fig.4

Material properties change with temperature"

Fig.5

Simulation calculation process"

Fig.6

Comparison of simulation results and experimental results"

Fig.7

Comparison of macroscopic image of experiment and simulated joint cross-sections"

Fig.8

Temperature field distributions at 0.6 s"

Fig.9

Temperature distribution at the welding interface under different welding times"

Fig.10

Dynamic change in friction coefficient"

Fig.11

Plastic strain distribution in welded cross-section at different welding time"

Fig.12

Dynamic change of ultrasonic softening coefficient"

Fig.13

Comparison of simulation results of plastic deformation of welding cross section"

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