Ultrasonic metal welding is widely used for joining multiple layers of dissimilar metals, such as aluminum/copper battery tabs welding onto copper busbars. It is therefore important to have a robust product/process design using ultrasonic metal welding that ensures consistent welds with desired quality. In this work, the effects of longitudinal and flexural vibrations of the battery tab during ultrasonic welding on the development of axial normal stresses that occasionally cause cracks near the weld area are studied by applying a one-dimensional continuous vibration model for the battery tab. Analysis results indicate that fracture could occur near the weld area, due to low cycle fatigue as a result of large dynamic stresses induced by resonant flexural vibration of the battery tab during welding. This study provides a fundamental understanding of battery tab dynamics during ultrasonic welding and its effects on weld quality, and can be used to develop guidelines for product/process design of ultrasonically welded battery tabs.
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August 2014
Research-Article
Dynamic Stress Analysis of Battery Tabs Under Ultrasonic Welding
Bongsu Kang,
Bongsu Kang
1
Engineering Department,
Indiana University–Purdue
e-mail: kang@engr.ipfw.edu
Indiana University–Purdue
University Fort Wayne
,Fort Wayne, IN 46805
e-mail: kang@engr.ipfw.edu
1Corresponding author.
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Wayne Cai,
Wayne Cai
Advanced Propulsion Manufacturing
Research Group,
Manufacturing Systems Research Lab,
e-mail: wayne.cai@gm.com
Research Group,
Manufacturing Systems Research Lab,
General Motors Global R&D Center
,Warren, MI 48090
e-mail: wayne.cai@gm.com
Search for other works by this author on:
Chin-An Tan
Chin-An Tan
Search for other works by this author on:
Bongsu Kang
Engineering Department,
Indiana University–Purdue
e-mail: kang@engr.ipfw.edu
Indiana University–Purdue
University Fort Wayne
,Fort Wayne, IN 46805
e-mail: kang@engr.ipfw.edu
Wayne Cai
Advanced Propulsion Manufacturing
Research Group,
Manufacturing Systems Research Lab,
e-mail: wayne.cai@gm.com
Research Group,
Manufacturing Systems Research Lab,
General Motors Global R&D Center
,Warren, MI 48090
e-mail: wayne.cai@gm.com
Chin-An Tan
1Corresponding author.
Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received September 12, 2013; final manuscript received February 19, 2014; published online May 21, 2014. Assoc. Editor: Tony Schmitz.
J. Manuf. Sci. Eng. Aug 2014, 136(4): 041011 (8 pages)
Published Online: May 21, 2014
Article history
Received:
September 12, 2013
Revision Received:
February 19, 2014
Citation
Kang, B., Cai, W., and Tan, C. (May 21, 2014). "Dynamic Stress Analysis of Battery Tabs Under Ultrasonic Welding." ASME. J. Manuf. Sci. Eng. August 2014; 136(4): 041011. https://doi.org/10.1115/1.4026990
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