A Study of Investigation and Optimization of Process Parameters On Ultrasonic Metal

Mechanical Engineering

This paper speaks about the, joining of two delrin materials (plastic material) using ultrasonic welding. There are two types of parameters. They are machine setting initial parameters and running parameters. The running parameters have a large impact on the weld strength. The welding was carried out by varying its parameters such as weld time, weld hold time, weld delay time to evaluate the strength of the weld. After welding of the specimens, various tests were done on the welded materials to check the weld strength of the material. The tensile strength of the material gets better by optimizing the running parameters. The major application of this material is, it is used in impeller. Response surface method (RSM) with genetic algorithm (GA) RSM is utilized to develop an effective model to predict weld strength by incorporating process parameters such as pressure, weld time and amplitude. Experiments were conducted as per central composite face centered design for spot and seam welding of 0.2 and 0.3 mm thick copper and brass specimens. An effective second order response surface model is developed by utilizing experimental measurements. Response surface model is further interfaced with the GA to optimize the welding conditions for desired weld strength. Optimum welding conditions produced from GA is verified with the experimental results and is found to be in good agreement.

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