Research On Ultrasonic Bonding System For Metal Foil

Ultrasonic metal consolidation technology plays an increasingly important role in aerospace,smart materials,additive manufacturing and other fields.The improvement of ultrasonic vibration system performance is the key issue of this technology.The push-pull ultrasonic vibration system has the advantages of high power,large output amplitude,and stable operation,and it meets the demand for ultrasonic consolidation of metal foils.Because the tool head needs to be specially designed to meet the needs of different workpieces.In this paper,the ultrasonic vibration structure of the push-pull dual transducer is taken as object,and the influence of the critical structural parameters on the characteristics of the vibration system is studied.The design requirements(frequency 20 kHz,consolidation width not less than 20 mm,output amplitude not less than 10?m)are taken as Technical goals,dynamic optimization of structural parameters,establishment of optimized design methods,and experimental verification.The specific research is as follows:For the design requirements(resonance frequency 20 kHz,amplitude is not less than 5?m),the basic structural parameters of the transducer are designed through calculation and simulation.According to the design principle of the stepped horn and the engineering experience analogy,the design of the horn and the tool head is combined with the structural parameters of the transducer to determine the structural parameters thereof.Using ANSYS APDL to establish a parametric model analysis method to study the impact of structural parameters on the output characteristics,and optimize the model.The optimized result is the resonant frequency of 19391.7Hz and the amplitude of the drive is 200 V.After the optimization of the overall vibration system parameters,the resonance frequency is 19641Hz(the deviation rate is 1.795%),the output amplitude reaches 18.17?m>10?m at 200 V,and the consolidation width of the tool head is 25 mm,which meets the design requirements.Based on the above design,analysis and optimization,a complete push-pull ultrasonic metal consolidation system was obtained and a prototype was produced.The impedance of the transducer was measured by the analysis of the resonant frequency of 19875 Hz,and the output amplitude was about 9.67?m driven by 200 V voltage.The ultrasonic consolidation system was measured by a threedimensional laser vibrometer.The resonance frequency was 20055 Hz and the output amplitude was 18.36?m>10?m,which meets the original design parameters,There is a deviation of 1.1% from the simulation result,which verifies the design and optimization scheme has a certain engineering significance.