Anvil Design and Experimental Investigation for Ultrasonic Welding of Thin Dissimilar Metals

Abstract

Ultrasonic Welding (USW) is a solid-state bonding process that produces joints by allowing transfer of high frequency vibratory energy in to the work pieces which are brought together under pressure. The whole process is done without melting of any of the material. It can be used as a micro-welding technique which is being widely used for vehicles, shipbuilding, and the welding of electric and electronic parts. Ultrasonic tooling is one which greatly affects the performance of whole welding system. Anvil is an important part which includes in ultrasonic tooling. Design of anvil is peculiarly based on the geometry. Very few studies are done on the effect of welding process on the geometrical changes of the anvil. In this work, ultrasonic anvil was designed in two different geometrical shapes with same material SS 304, which was then fabricated by series of operations and investigated the effects of Tensile strength, T-peel strength and weld quality. The experimental design was done in Taguchi method using L9 orthogonal array and MOORA method was used to convert the multiobjective optimization problem to single one. Then, Taguchi method was further used to optimize the response parameters.