AN OPTIMIZATION STUDY OF THE ULTRASONIC WELDING OF THIN FILM POLYMERS

摘要

In manufacturing industries, ultrasonic welding has established itself as one of the most effective techniques for fusing plastic assemblies due to its rapid performance and the absence of filler material. In this report, a thermoplastic polyurethane prototype of an orthopedics device that requires a hermetic seal is joined using ultrasonic welding. A robust design approach is used to study the manufacturing control factors that influence the process. The welding process factors and their interactions are used to characterize the resulting seal. Burst testing is used to assess weld strength. Optical microscopy in addition to SEM images, are used for a qualitative evaluation of the welded joint. Optimum process parameter settings from the robust design study deliver a strong and leak-proof weld.