Mechanical Analysis of Ultrasonic Bonding for Rapid Prototyping

[+] Author and Article Information
Yuan Gao, Charalabos Doumanidis

Department of Mechanical Engineering, Tufts University, Medford, MA 02155

J. Manuf. Sci. Eng 124(2), 426-434 (Apr 29, 2002) (9 pages) doi:10.1115/1.1459082 History: Received November 01, 2000; Revised August 01, 2001; Online April 29, 2002
Copyright © 2002 by ASME
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Laboratory station for ultrasonic prototyping (A) ultrasonic welder (B) positioning table (C) end-mill cutter (D) electronic drivers (E) power supply (F) control computer
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Schematic arrangement of ultrasonic rapid prototyping
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Arrangement of numerical model and boundary conditions
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Analytical plane stress model
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Experimentally identified history of friction coefficient μ(t) during one weld
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Longitudinal section and top view of equivalent strain field eeq
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Saturation of shear stress |ty|≤μ(t)p as coefficient μ(t) varies (0.34–0.58)
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Equivalent stress field εeq at three steps of one ultrasonic cycle
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Laboratory and computational transients of stress Exx(t) during one weld
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Longitudinal displacement amplitudes across thickness (lengths not to scale for clarity)
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Propagation of plastic deformation region (a) initiation in the top foil (b) initiation in the substrate (c) propagation in substrate
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Layered load cell/heat flux meter by ultrasonic prototyping



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