Molding Process
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COC Ultrasonic Welding Fragmentation
Problembeschreibung
During ultrasonic welding of COC parts, the weldment fragments or the welding strength fluctuates, and cracks and pulverization appear in the horn contact area.
Ursachenanalyse
COC has high rigidity and high brittleness, and ultrasonic vibration energy easily causes fragmentation at stress concentration points; excessive welding amplitude or unreasonable weld line design causes local energy overload; improper near-field and far-field selection.
Lösung
①Reduce the amplitude and adjust the welding energy in stages; ②optimize the design of the weld line energy director; ③ensure good fitting support between the horn and the fixture; ④evaluate switching brittle structures to hot plate or laser welding.
Wichtigste Erkenntnis
COC ultrasonic welding requires a low-energy fine process; the weld line design of brittle materials determines the energy distribution; when the process window is narrow, alternative welding methods should be evaluated.; After confirming effectiveness, fix the parameters and practices into the work instruction to prevent recurrence
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