Ultrasonic metal welding is often used as a rapid and effective technique for joining sheet metals without causing them to melt. Precise management of the welding process parameters is crucial for achieving excellent joint quality. However, modeling the behavior of the weld material and the welding process is still very challenging. This study aimed to create 3D finite element models that accurately simulate the ultrasonic metal welding process. The proposed material model integrates frictional heat and ultrasonic softening, as well as the cyclic plasticity model. A friction law incorporating a variable friction coefficient is examined to investigate surface impacts. This coefficient is influenced by contact pressure, slippage, temperature, and the number of cycles. The findings of this study demonstrate that the oscillation frequency significantly influences both the temperature fluctuation and the extent of the heat-affected zone. Increased frequencies lead to accelerated temperature fluctuations and expanded heat-affected. Furthermore, ultrasonic welding combined with preheating led to a much wider heat-affected zone than ultrasonic welding without heating. The minimum preheating temperature required for ultrasonic welding of aluminum is 150 °C. This model can predict the relative displacement between welded plates. Assessing the oscillations that arise during the ultrasonic welding process is beneficial in selecting suitable welding settings to prevent excessive heating. This aids engineers in choosing appropriate welding parameters to avoid excessive heat generation during ultrasonic welding, hence limiting the reduction in tensile strength of the weld. Consequently, it can decrease the expense of the experimental methodology.

My Nu Ho Thi

Cao Ky Dinh Le

Truyen Le The

JOURNAL OF MECHANICAL ENGINEERING AND SCIENCES

The Journal of Mechanical Engineering & Sciences "JMES" (ISSN (Print): 2289-4659; e-ISSN: 2231-8380) is an open access peer-review journal (Indexed by Emerging Source Citation Index (ESCI), WOS; SCOPUS Index (Elsevier); EBSCOhost; Index Copernicus; Ulrichsweb, DOAJ, Google Scholar) which publishes original and review articles that advance the understanding of both the fundamentals of engineering science and its application to the solution of challenges and problems in mechanical engineering systems, machines and components. It is particularly concerned with the demonstration of engineering science solutions to specific industrial problems. Original contributions providing insight into the use of analytical, computational modeling, structural mechanics, metal forming, behavior and application of advanced materials, impact mechanics, strain localization and other effects of nonlinearity, fluid mechanics, robotics, tribology, thermodynamics, and materials processing generally from the core of the journal contents are encouraged. Only original, innovative and novel papers will be considered for publication in the JMES. The authors are required to confirm that their paper has not been submitted to any other journal in English or any other language. The JMES welcome contributions from all who wishes to report on new developments and latest findings in mechanical engineering.

The Journal of Mechanical Engineering and Sciences (ISSN (Print): 2289-4659; e-ISSN: 2231-8380) is an open access peer-reviewed journal indexed by the Emerging Source Citation Index (ESCI), WOS, SCOPUS Index (Elsevier), EBSCOhost, Index Copernicus, Ulrichsweb, DOAJ, and Google Scholar. It publishes original and review articles that enhance the understanding of the fundamentals of engineering science and its applications in addressing challenges and problems in mechanical engineering systems, machines, and components. The journal particularly focuses on demonstrating engineering science solutions to specific industrial issues. We encourage original contributions that provide insights into analytical methods, computational modeling, structural mechanics, metal forming, the behavior and application of advanced materials, impact mechanics, strain localization, and other nonlinear effects, fluid mechanics, robotics, tribology, thermodynamics, and materials processing. Only original, innovative, and novel papers will be considered for publication in JMES. Authors are required to confirm that their paper has not been submitted to any other journal in English or any other language. JMES welcomes contributions from all who wish to report on new developments and the latest findings in mechanical engineering.

《Journal of Mechanical Engineering and Sciences》（ISSN（印刷版）：2289-4659；电子版ISSN：2231-8380）是一本开放获取的同行评审期刊（被Emerging Source Citation Index（ESCI）、WOS、SCOPUS Index（Elsevier）、EBSCOhost、Index Copernicus、Ulrichsweb、DOAJ、Google Scholar等索引），旨在发表原创和综述文章，以推动对工程科学基础及其在机械工程系统、机器和组件中的应用理解的深入。期刊特别关注工程科学解决方案在特定工业问题中的应用。我们鼓励提供对分析、计算建模、结构力学、金属成形、先进材料的行为与应用、冲击力学、应变局部化及其他非线性效应、流体力学、机器人技术、摩擦学、热力学和材料加工等领域的深入见解的原创贡献。只有原创、创新和新颖的论文将被考虑在JMES上发表。作者需确认其论文未提交给任何其他英文或其他语言的期刊。JMES欢迎所有希望报告机械工程领域新发展和最新发现的贡献。

Three-dimensional simulation of finite element ultrasonic welding of aluminum alloy AA-6061

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Journal Info

Category	Quartile
ENGINEERING, MECHANICAL	4