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VibrationforPlasticsJoiningTheoryandApplicationHandb.VibrationRZ.e12.10.200110:45UhrSeite3Likeallthermaljoiningtechniques,linearvibrationweldingisparticularlyapplication-oriented:Itgoeswithoutsayingthatapplicationtestsareamust,inadditiontoadvisorysupport.Therefore,BRANSONconductvibrationweldingtestsintheirownlaboratoriescapableofsolvingalsoyourproblembydetailingallrelevantquantityandqualityfactors.Theapplicationrequestshouldcontainspecificdataallowingthetesttobeconductedwithoutdelay.Thepurposeofthebookletittoprovidecustomersandprospectivecustomerswithinformationandadvice.Allstatementscontainedarebonafideinformationprovidedtothebestofourknowledge,andshallnotgiverisetoanyclaims.Asourproductsarecontinuouslybeingfurtherdeveloped,theyaresubjecttotechnicalmodifications.AllrightsreservedbyBRANSONconcerningtheuseofapplication-specificdocumentscontained.04/023.02e31.WhatcanbeachievedbyVibrationWelding?1.1-Joint1.2-Combinationsofmaterials1.3-Weldtime1.4-Jointstrenghts1.5-Tightness2.WhatisVibrationWelding?2.1-Principle2.2-Operation2.3-Comparisonwithotherweldingtechniques3.BRANSON'sapproachtoasuccessfulVibrationTechnology3.1-Vibrationhead3.2-Lifttable3.3-Control3.4-Construction(standardversion)3.5-Specialdesignconcepts3.6-Technicalspecifications4.Designcriteria4.1-General4.2-Jointandpartdesign5.Fixtures5.1-Requirements5.2-Design5.3-Careandmaintenance6.Qualityassurance6.1-Control6.2-Theparametersinfluencingweldquality6.3-Troubleshooting7.Customersupport7.1-BRANSONsoftware7.2-Thedevelopmenttowardsthefinishedpart8.Applicationexamplesandfuturetrends8.1-Currentapplications9.BRANSONInternationalContents51.WhatcanbeachievedbyVibrationWelding?1.1JointLinearvibrationweldingisbasedontheprincipleoffrictionalheatgeneratedatthesurfacesofthejoint.Thepartsmoverelativetoeachotherwithpredeterminedweldingpressureandpeak-to-peakampli-tude.Consequently,thepartsmustallowalinearmovementrelativetoeachotheratacorrespondingamplitude.Fig.1Fig.2However,withappropriatepartgeometries,anddependentuponthethermoplasticresinused,theplaneofthejointmaybeinclined10degreesrelativetothevibratorydirec-tion.6Weldingoperationisalsopossibleintheverticalplane.Theweldingpressuremustbeappliedlaterally(fig.3and4).Fig.3Example:TheweldingofanairducttoadashboardcarrierFig.4Example:Theweldingofarein-forcementtoabumper7Furtherpossibilitiesaretheweldingofplasticfoilstocarpetornon-wovenmaterialsandthecompregnatingofpilecarpets.Therelevantapplicationsareautomobilefootmatsandbordertrimsofcarpetandnon-wovenmaterials.Newapplicationareasincludethejoiningof:-Woodfibrecarrierwiththermoplasticresin-Textilefibrecarrierwiththermoplasticresin-Polyurethanelongfibrecarrierwithther-moplasticresinThebondachievedbetweentheplasticmaterialandthecarrierisduetotheclaweffect.Furthermore,textilegauzeandpilecar-petscanbecompregnatedbymeansofvibration.Fig.5Drawingsshowingthepossiblejoints81.2.CombinationsofmaterialsAllknownthermoplasticresinsareweld-ablebymeansofvibrationtechniques,includingmaterialswithfillerportionsofupto45percent.Bothpracticalsolutionstoapplicationproblemsandlaboratorytestsprovedthatplasticsofdifferenttypesallowtheuseofweldingtechniquestoachievesatisfactorybondingcharacteristics.Thefollowingtablegivesalistofthebestknowntypesofplasticswithrespecttotheirweldability.Newcombinationsmayconstantlybeaddedinthecourseoffuturedevelopment.Itwillbepossibleforthereaderofthistabletobringituptodatebyenteringcurrenttestresults.9Compatibilityofthermoplasticmaterialsinviewofwelding101.3WeldingtimeThefollowingtableshowsthetimesvibra-tionweldingoperationstakeincomparisonwithotherjoiningtechniques.Theseweldingtimesareapproximateval-ueswhichmayvarywitheachapplication.WeldingtechniqueUltrasonics0,05to2VibrationLinear1to10VibrationOrbital0,5to8HotPlate10to20Angular0,2to10Rotation0,1to10Tapeweld6to15(resistance)Emaweld5to60(inductance)Weldtimeinseconds10203040111.4.Jointstrengths1.4.1Vibrationjoints1.4.1.1TensileStrengthMaterial:Polypropylene,non-reinforcedandreinforced,orwithfillers.Jointarea:196mm²Fig.6TestspecimenVibrationwelding:Tensilestrengthinthejointarea12Material:Glass-matreinforcedpoly-propyleneonpolyproylene-reinforced-non-reinforcedJointarea:300mm²Fig.7TestspecimenVibrationwelding:Tensilestrengthinthejointarea131.4.1.2ShearstrengthMaterial:Polypropylene,non-reinforcedandreinforced,orwithfillers.Jointarea:406mm²Testprocedure:ModifieddroptestFig.8TestspecimenVibrationwelding:Tensilestrengthinthejointarea141.4.2VibrationbondsMaterial:-ABSwithWoodfibre-Polyurethane-Longglassfibre-TextilefibreJointarea:300mm²Fig.9TestspecimenTensilestrengthinthejointarea:Thetensilestrengthsachievedasshowninthegrapharebasedontheclaweffectofthethermoplasticresinonthecarrier.Theyaredependentonthestructureofthecarrierused.151.5TightnessExample:GasolinereservoirMaterial:Polyoxymethylene(POM)Wallthickness:2.5mmTest:Reservoirtestedfor0.7bartightnessina20°CwaterbathTherequirementsweremetwiththefollowingsetofparameters:Weldingfrequency=240HzWeldingtime=4.5secondsHoldtime=1.5secondsAmplitude=0.9mmFig.10:Gasolinereservo