This paper presents a tool wear monitoring framework for ultrasonic metal welding which has been used for lithium-ion battery manufacturing. Tool wear has a significant impact on joining quality. In addition, tool replacement, including horns and anvils, constitutes an important part of production costs. Therefore, a tool condition monitoring (TCM) system is highly desirable for ultrasonic metal welding. However, it is very challenging to develop a TCM system due to the complexity of tool surface geometry and a lack of thorough understanding on the wear mechanism. Here, we first characterize tool wear progression by comparing surface measurements obtained at different stages of tool wear, and then develop a tool condition classification algorithm to identify the state of wear. The developed algorithm is validated using tool measurement data from a battery plant.
- Manufacturing Engineering Division
Tool Wear Monitoring for Ultrasonic Metal Welding of Lithium-Ion Batteries
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Shao, C, Kim, TH, Hu, SJ, Jin, J(, Abell, JA, & Spicer, JP. "Tool Wear Monitoring for Ultrasonic Metal Welding of Lithium-Ion Batteries." Proceedings of the ASME 2015 International Manufacturing Science and Engineering Conference. Volume 2: Materials; Biomanufacturing; Properties, Applications and Systems; Sustainable Manufacturing. Charlotte, North Carolina, USA. June 8–12, 2015. V002T05A022. ASME. https://doi.org/10.1115/MSEC2015-9428
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