CAEDSInjectionCastingDesign

Ultrasonicweldingjoints
TampereUniversityofTechnologySannaNyknen

Ultrasonicweldingisthemostcommonusedweldingmethodforjoiningofinjec General
tion moulded parts together. The joint design of the two parts to be welded is

important and has to be taken into account when designing injection moulded

parts.








Figure1: Joiningoftwo
plasticpartsbyultrasonic
welding.Amplitude=2540m
andfrequency=2040kHz.
BasedonJrveletal.:Ruisku
valu,page323.


Inultrasonicweldingshortamplitudelongitudinalvibration(frequency2040kHz
andamplitude2540m)isdirectedtotheweldedparts.Partsbegintovibrate,the
energydirectormeltsandpartsjointogether.Weldingtimeisusually0.11.0s.The
plasticpartsareattachedbetweensonotrodes.
Basicdesignrules
Therearesomebasicdesignrulesforultrasonicwelding: forultrasonic
Amorphousmaterialsarebetterforultrasonicweldingthanpartiallycrys welding
talmaterials.
Itisimportantthatpartsaredesignedinawaythatpartsarefunnelled
straightandweldedsurfaceisenoughplanar(0.2mm)
Whendesigningenergydirectors,itisimportanttonoticemutualorienta
tion.

Energydirectorsareusuallytriangleshaped.Theycanbeconsistedofagroupof Energydirectors
conesortheycanbecontinuousridges.Theaimisthattheheadofatriangleisas
sharp as possible so that tension amplitude would be high and melting of the
materialwouldstartassoonaspossible.
The shape and size of energy director are depended on welded material. Usually
partially crystal materials need larger energy director than amorphous materials.
Inpractiseonamorphousplasticstheheightofenergydirectorvariesbetween0.2
0.6 mm and on partially crystal plastics and on polycarbonate and polysulfone
between 0.41 mm. The width of energy director varies on amorphous plastics
between0.251.5mmandonpartiallycrystalplasticsbetween0.251.3mm.
Weldingthickwalledparts(>6mm)itispossibletousetwoormoreenergydirec
torssidebyside.Inthecornersoftheweldingline,theenergydirectorshouldbe
rounded or cut of so that material does not gather regionally or molten material
extrude.

Ultrasonicweldingjoints1
 CAEDSInjectionCastingDesign

Recommended
Table1: Energydirectionondifferentmaterials.BasedonRakkola:Ultranihitsaus,page dimensionsfor
113. energydirectors
Material Angle() Height(%)*) Width(%)**)

Amorphous 90 5060 1025

PC 60 85 1025

PMMA 60or90 85 1025

PSU 60

Partially 60 50or85 1025
crystalline

*)Ofwidthofenergydirectorsbase
**)Ofwallthickness

Buttjointisthesimplestandmostusedjointtype.Itisalsothesimplestjointtype Buttjoint
forinjectionmoulding.









Figure2: Dimensioningofabuttjoint.

W=wallthickness.BasedonRakkola:Muovien

ultranihitsaus,page114.


Steppedjointisadevelopedversionofbuttjoint.Steppedjointisusedwhengood Steppedjoint
cosmeticlookisneededfromthejoint.Flashisdevelopedonlytoonesideofjoint
becauseextrameltflowstothegapbetweentheparts.

Figure3: Ontheright:Asteppedjoint,whereflashisformedinsideoftheproduct.
Ontheleft:Asteppedjointwhereflashisformedoutsideoftheproduct.BasedonRakkola:
Muovienultranihitsaus,page115.

Ultrasonicweldingjoints2
 CAEDSInjectionCastingDesign

Intonguechanneljointupperpartsbracket(tongue)penetratesintothechannelof Tonguechannel
lower pat. There will be no flashes. Joint creates lots of requirements for injection joint
mouldinganddimensionalaccuracyofparts.







Figure4: Dimensioningofatonguechanneljoint.
W=wallthickness.BasedonRakkola:Muovienultrani
hitsaus,page116.


Inashearjointtheregionofcontactbetweenpartsisverysmallatfirst.Itiscom Shearjoint
posedonwhenanotherpartssteptouchesanotherpart(theyhaveanegativefit).
Touching surfaces start to melt and parts join together while melting of vertical
wallcontinues.Formedjointisthereforevertical.

Figure5: Dimensioningofashearjoint.a=
0.0250.05mm,b=min.1mm,c=s/10s/5,h=s/3
1.5s.BasedonRakkola:Muovienultranihitsaus,
page119.

Shear joint is usually used when strength and hermetic is needed. It is the only
possible joint type for partially crystalline plastics. Parts tolerances should be so
small that amount of molten material would stay as constant as possible during
welding.Iftherecannotbevisibleflashesinthepart,thejointhavetobedesigned
sothatthemoltenmaterialcanflowtothegapbetweenparts.

Beadshearjointissuitableforjoiningacuteangledandrectangularparts.Thejoint Beadshearjoint
ishermeticandtherewillbenovisibleflashesbutthestrengthofthejointhasbeen
lowered.




Figure6: Dimensioningofabeadshear
joint.BasedonRakkola:Muovienultranihitsaus,
page121.

Ultrasonicweldingjoints3
 CAEDSInjectionCastingDesign

Mashjointisajoiningmethodformaterialslikepolyamidesandacetalsthatchange Mashjoint
theirstatequicklyfromsolidtoliquid.Thejointishermeticandthestrengthofjoint
isgreaterthanintraditionalshearjoint.




Figure7: Dimensioningofamashjoint.
BasedonRakkola:Muovienultranihitsaus,
page121.

Inultrasonicweldedpartsallcornershavetoberoundedifitispossible.Therewill Shapeofapart
bestressconcentrationsinsharpcorners.Roundingradiusshouldbeatleast0.20.5
mm. Any protruding parts like ribs or pins can get broken during welding. This
canbeavoidedbymakingroundinginthejunctionofprotrudingparts,theycanbe
supported during welding or their width can be increased. Also inserts can get
brokenduringwelding.


Figure8: Allthecornersshouldbe
rounded.BasedonRakkola:Muovienul
tranihitsaus,page122.

Figure9: Protrudingpartscanget
brokenduringwelding.BasedonRakkola:
Muovienultranihitsaus,page122.

References

Brown,DesignandManufactureofPlasticParts,Wiley.
Jrveletal.,Ruiskuvalu,Plastdata,Tampere,2000.
Rakkola,Ultranihitsaus,Plastdata,Tampere,2003.

Ultrasonicweldingjoints4