Ultrasonic bonding of thin foils has been recently introduced to rapid prototyping of complex-shaped and/or internally structured layered parts. This article provides the mechanical analysis of an elementary ultrasonic spot welding process of a metal foil on a previously deposited substrate. A 2-D, quasi-static/dynamic, elasto-plastic numerical model of the stress/strain field is developed by finite element analysis. Its frictional boundary conditions at the foil/substrate interface are described via a simpler plain stress, static analytical formulation, and identified experimentally by strain measurements on the substrate surface, adjacently to the ultrasonic probe. The calibrated computational simulation is validated in the laboratory and applied in studying the elastic stress concentrations, plastic deformation initiation and propagation patterns, the slippage at the interface surface and the dynamic effects of ultrasonic loading on the bonding process. This mechanical model is suitable for analysis of multi-joint ultrasonic rapid prototyping and its applications in fabrication of multi-material, functional internal structures with embedded components.
Skip Nav Destination
Article navigation
Technical Papers
Mechanical Analysis of Ultrasonic Bonding for Rapid Prototyping
Yuan Gao,
Yuan Gao
Department of Mechanical Engineering, Tufts University, Medford, MA 02155
Search for other works by this author on:
Charalabos Doumanidis
Charalabos Doumanidis
Department of Mechanical Engineering, Tufts University, Medford, MA 02155
cdoumani@tufts.edu
Search for other works by this author on:
Yuan Gao
Department of Mechanical Engineering, Tufts University, Medford, MA 02155
Charalabos Doumanidis
Department of Mechanical Engineering, Tufts University, Medford, MA 02155
cdoumani@tufts.eduContributed by the Manufacturing Engineering Division for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received November 2000; revised August 2001. Associate Editor: M. Wang.
J. Manuf. Sci. Eng. May 2002, 124(2): 426-434 (9 pages)
Published Online: April 29, 2002
Article history
Received:
November 1, 2000
Revised:
August 1, 2001
Online:
April 29, 2002
Citation
Gao , Y., and Doumanidis, C. (April 29, 2002). "Mechanical Analysis of Ultrasonic Bonding for Rapid Prototyping ." ASME. J. Manuf. Sci. Eng. May 2002; 124(2): 426–434. https://doi.org/10.1115/1.1459082
Download citation file:
Get Email Alerts
Special Issue on the State-of-the-Art in Japanese Manufacturing Research
J. Manuf. Sci. Eng
A Review of Advanced Roll-to-Roll Manufacturing: System Modeling and Control
J. Manuf. Sci. Eng (April 2025)
Related Articles
Finite Element Analysis of Welding Processes by Way of Hypoelasticity-Based Formulation
J. Eng. Mater. Technol (April,2011)
Ultrasonic Welding Simulations for Multiple Layers of Lithium-Ion Battery Tabs
J. Manuf. Sci. Eng (December,2013)
3-D Finite Element Modeling of the Welding Process Using Element Birth and Element Movement Techniques
J. Pressure Vessel Technol (May,2003)
Investigation of Fatigue Strength of Welded Tube-to-Tubesheet Joint
J. Pressure Vessel Technol (August,2009)
Related Proceedings Papers
Related Chapters
Concluding Remarks and Future Work
Ultrasonic Welding of Lithium-Ion Batteries
Microstructure Evolution and Physics-Based Modeling
Ultrasonic Welding of Lithium-Ion Batteries
Defining Joint Quality Using Weld Attributes
Ultrasonic Welding of Lithium-Ion Batteries