International Journal of Engineering Research & Technology (IJERT)

ISSN: 2278-0181
Vol. 2 Issue 3, March - 2013

Parametric Effect Of Ultrasonic Plastic Welding On Tensile Strength

For ABS, Acrylic And Polycarbonate Materials.

Sunilkumar K. Patel1, Prof. Dhaval M. Patel2

1. P. G. Student 2. Associate Professor, U. V. Patel College of Engineering, Ganpat
University, Kherva, Mehsana.

ABSTRACT:
Engineering thermoplastics have found wide resistance and light weight make them a
applications in automotive, aerospace, very useful material in many industries,
electronics, medical, and other domestic namely, automotive, aerospace, electronics,
appliance industries. Therefore the joining medical, and other domestic appliance
of the thermoplastics has become an industries. Increased use of engineering
important manufacturing operation. In near plastics has occurred in several industries;
field ultrasonic plastic welding the distance hence joining of these materials becomes an
between the horn and the weld interface is important manufacturing operation. The
less than 6mm.The near field ultrasonic techniques available for joining plastics are
plastic welding of polycarbonate, acraylic (1) mechanical joining (screws, rivets, pin
RRTT
and ABS material are studied. The taguchi fasteners, and retaining rings (2) adhesive
method is used for experiment analysis. We bonding and (3) welding. Mechanical
joining offers an advantage in that the joints
IIJJEE

study the different parameter which is

affected on the weld tensile strength. There are not permanent. But the insertation of a
are mainly two parameters which is affected foreign material through a mounting hole
on the weld tensile strength one is pressure gives rise to stress concentrations.
and other is weld time.We analysis of weld Mechanical fasteners also increase the
tensile strength for above two parameters. overall weight of the structure. Adhesive
During this analysis use 20kHz frequency bonding is a process where an adhesive, e.g.
for ultrasonic welding machine. Epoxy is placed between the parts and
allowed to cure with time. This produces a
1.0 Introduction: joint of adequate strength. Although
Engineering plastics which belong to adhesive bonding offers good strength in
the broad family of polymers are those shear, its tensile, bending, and peeling
materials which posses high strength, high strength are low. If the joint is not design
toughness, flame retard ant characteristic, properly there is also the problem of stress
good rigidity and durability. These concentration. The welding of plastics offer
combined with other attractive features such distance advantages in terms of weight
as excellent insulation properties, corrosion savings and with good joints designs and

www.ijert.org 1
 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
Vol. 2 Issue 3, March - 2013

proper process control it provides excellent In booster booster this vibration signal is
joint strength [1]. amplified as par requirement. This amplified
There are a number of processes for welding signal is transfer to the horn. In the horn this
thermoplastics. Hot gas, hot plate, resistance signal is converted into mechanicalvibration.
implant, and induction implant require an This mechanical vibration is used to produce
external heating source. Ultrasonic welding the friction between the adjusting layers.
friction welding, and vibration welding rely
on the heat generated by the mechanical 3.0 Ultrasonic plastic welding:
movement within or between the parts [1].

2.0 Experimental Procedures:

The experiments were conducted on
ultrasonic plastic welding machine. The
welding is conducted on three different
material abs, polycarbonate and acrylic. In
ultrasonic welding, ultrasonic vibrations
created a friction-like relative motion
between two surfaces that are held under
RRTT
pressure. The power is supplied to the
piezoelectric base transducer. The Figure 1.3 Ultrasonic plastic welding
IIJJEE

transducer produces the vibration. This processes

vibration is transfer to the booster.
Ultrasonic plastic welding is the joining or
reforming of thermoplastics through the use
of heat generated from high-frequency
mechanical motion. It is accomplished by
converting high-frequency electrical energy
into high-frequency mechanical motion.
That mechanical motion, along with applied
force, creates frictional heat at the plastic
components' mating surfaces (joint area) so
the plastic material will melt and form a
molecular bond between the parts. Plastics
assembly is a fast, clean, efficient, and
repeatable process that consumes very little
Fig.1 Ultrasonic plastic welding machine energy. No solvents, adhesives, mechanical
fasteners or other consumables are required

www.ijert.org 2
 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
Vol. 2 Issue 3, March - 2013

and, or other consumables are required, and 4.0 Ultrasonic plastic welding
finished assemblies are strong and clean. machine specification:

3.1 Ultrasonic plastic welding advantages:

Parameter Range
Ultrasonic metal welding exhibits
unique welding properties that include: Model no 3000-1500
 Excellent electrical, mechanical, and
Closing force(max) 3000N
thermal connections between similar
and dissimilar metals Generator SG-22-1500
 Low heat buildup during the
ultrasonic process (no annealing of Ultrasonic output
1.5 KW
materials). power
 Compensation for normal surface
Frequency 20 KHZ
variations of the material.
Max stroke 100 mm
 Ability to clean surface oxides and
contaminants prior to welding. Throat depth 275 mm
RRTT
 Ability to weld large areas using Working table 465×410mm2
minimal energy.
IIJJEE

Aluminum
 Ability to weld thin materials to
alloy 7049, E
thick materials.
Horn size (Mpa)=72398,
 Low cost per weld
Density=2850
 A sufficient energy input into the
Kg/m3
joining area has to be possible. Small
Max pressure 10 bar
joining areas (<1 mm ²) must be
realizable. Max weld time 2.5 sec

 The reproducibility and the Ultrasonic transducer

9 mm
positioning accuracy have to be very capacity
high.
Ultrasonic booster
 Flash should be as small as possible 1:2
capacity
in order to ensure the functionality of
the micro system. Table 2 : Parameter of Ultrasonic plastic
welding machine

www.ijert.org 3
 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
Vol. 2 Issue 3, March - 2013

5.0 Parameter Considered for 8 1.5 5.0 42.3

Experiment: 9 2.0 3.0 34.2
5.1 Input Parameters: 10 2.0 4.0 42.8

11 2.0 4.5 44.4

Factor Levels
No. Factors Levels
Values 12 2.0 5.0 46.7

1 WT 4 1, 1.5, 2.0, 2.5 13 2.5 3.0 40.9

2 WP 4 3, 4, 4.5, 5.0 14 2.5 4.0 45.8

Table 3: Input Parameter of Experiment. 15 2.5 4.5 48.3

Here, 16 2.5 5.0 42.6

WT = weld time (sec).
Table 5: Experimental Table for ABS
WP = weld pressure (bar).
Remaining all machine parameters are
considering constant. Sr no WT WP TS
RRTT
6.2 Output Parameters:
1 1.0 3.0 20.3
IIJJEE

Here we are measuring only one output

2 1.0 4.0 25.1
parameter which is Tensile strength = TS
(Mpa). 3 1.0 4.5 28.3

6.3 Experimental Table: 4 1.0 5.0 30.9

Sr no WT WP TS 5 1.5 3.0 23.0

1 1.0 3.0 28.0 6 1.5 4.0 28.2

2 1.0 4.0 32.0 7 1.5 4.5 31.4

3 1.0 4.5 35.0 8 1.5 5.0 34.0

4 1.0 5.0 36.2 9 2.0 3.0 28.3

5 1.5 3.0 30.6 10 2.0 4.0 31.2

6 1.5 4.0 35.3 11 2.0 4.5 33.9

7 7 1.5 4.5 38.9 12 2.0 5.0 39.0

www.ijert.org 4
 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
Vol. 2 Issue 3, March - 2013

13 2.5 3.0 31.9 7.0 Analysis of Results and

14 2.5 4.0 40.0 Discussions:

15 2.5 4.5 38.3

16 2.5 5.0 36.1

Table 6: Experimental Table for Acrylic

material

Sr No WT WP TS

1 1.0 3.0 23.0

2 1.0 4.0 25.9

Fig: 2 Graph of pressure Vs. tensile strength at
3 1.0 4.5 27.0 weld time 1.0sec

4 1.0 5.0 29.0

5 1.5 3.0 26.9

RRTT
6 1.5 4.0 27.0
IIJJEE

7 1.5 4.5 32.8

8 1.5 5.0 34.9

9 2.0 3.0 33.6

10 2.0 4.0 37.9 Fig: 3 Graph of pressure Vs. tensile strength at

weld time 1.5sec
11 2.0 4.5 39.8

12 2.0 5.0 41.3

13 2.5 3.0 40.1

14 2.5 4.0 41.1

15 2.5 4.5 47.0

16 2.5 5.0 45.6

Table 7: Experimental Table for

Fig: 4 Graph of pressure Vs. tensile strength at
polycarbonate material
weld time 2.0 sec

www.ijert.org 5
 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
Vol. 2 Issue 3, March - 2013

the tensile strength is also increases,

but at that point the tensile strength
of polycarbonate material is slightly
higher as compared to the
polycarbonate material. At the last
point pressure 5.0 bar the tensile
strength of polycarbonate material
increases compared to the acrylic.
Fig: 5 Graph of pressure Vs. tensile strength at
(2) From the Fig 3 in which pressure Vs
weld time 2.5 sec
tensile strength for three different

(1) From the Fig 2 in which pressure Vs materials at constant weld time 1.5

tensile strength for three different sec is indicated. It is the comparison

materials at constant weld time 1.0 of three different material weld

sec is indicated. It is the comparison strength for same weld time 1.5 sec
RRTT
of three different material weld and same pressure. We Shows that

strength for same weld time 1.0 sec the tensile weld strength of abs
IIJJEE

and same pressure. We shows that material is higher compared to the

the tensile weld strength of abs two other material for same

material is higher compare to the condition. For abs material at

polycarbonate and acrylic for same pressure 3.0 bar the tensile strength

condition. For abs material at is 30.6 Mpa. When pressure is

pressure 3.0 bar the tensile strength increases 1 bar the tensile strength is

is 28.0 Mpa. When pressure is also increases 35.3 bar at constant

increases 1 bar the tensile strength is weld time 1.0 sec. If further increase

also increases 32.0 Mpa at constant of pressure 0.5 bar the tensile

weld time 1.0 sec. if further increase strength is increases at 38.9 Mpa. At

of pressure 0.5 bar the tensile the last for increase of pressure 1 bar

strength is increases at 35.0 Mpa. For the tensile strength is slighting

acrylic material at the pressure 3.0 increases 42.3 Mpa. For acrylic

bar the tensile strength is 20.3 Mpa. material at the pressure 1.0 bar the

Further increase of pressure 4.0 bar tensile strength is 23.0 Mpa which is

www.ijert.org 6
 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
Vol. 2 Issue 3, March - 2013

lower compared to the slighting increases. For acrylic

polycarbonate. Further increase of material at the pressure 3.0 bar the
pressure 2.0 bar the tensile strength tensile strength is 33.6. Further
is also increases at 28.2 Mpa which increase of pressure 4.0 bar the
is also lower than the polycarbonate tensile strength is also increases at
material. At the last point pressure 37.9 Mpa, at the pressure 4.5 bar the
5.0 bar the tensile strength of the tensile strength is also increases at
acrylic is increases at 34 Mpa but it 39.8 Mpa. At the last point pressure
is lower than the polycarbonate 5.0 bar the tensile strength is
material. increases at 41.3 Mpa. For poly
(3) From the Fig 4 in which pressure Vs carbonate also when we increase the
tensile strength for three different pressure gradually the tensile
materials at constant weld time 2.0 strength is also increase. At the last
sec is indicated. It is the comparison point pressure at 5.0 bar the tensile
RRTT
of different material weld strength strength is suddenly increases at 39.0
for same weld time 2.0 sec and same Mpa. In this graph we show that the
IIJJEE

pressure. We show that the tensile pressure effect on abs material is

weld strength of abs material is more effective than in polycarbonate
higher compared to the material.
polycarbonate material at initial first (4) From the Fig 5 in which pressure Vs
point. When pressure is increases 1 tensile strength for three different
bar the tensile strength is also materials at constant weld time 2.5
increases 42.8 Mpa in ABS material, sec is indicated. It is the comparison
while in polycarbonate material the of three different material weld
tensile strength is 31.2 Mpa which is strength for same weld time 2.5 sec
lower than the ABS at constant weld and same pressure. We show that the
time 2.0 sec. If further increase of tensile weld strength of abs material
pressure 0.5 bars the tensile strength is higher compared to the
is an increase at 44.4 Mpa in abs polycarbonate and acrylic material.
material. At the last for increase of For abs material at pressure 3.0 bar
pressure 1 bar the tensile strength is the tensile strength is 40.1Mpa.

www.ijert.org 7
 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
Vol. 2 Issue 3, March - 2013

When pressure is increases 1 bar the Sources of Percentage

tensile strength is also increases 45.8 Contribution
Variation
Mpa, at constant weld time 2.5 sec. (%)
If further increase of pressure 0.5
Factor – A Weld time 57.92
bars the tensile strength are increases
Factor – B Pressure 33.14
at 48.3 Mpa. But at the last for
increase of pressure 0.5 bar the Error 8.9332
tensile strength is suddenly decreases Total 100
at 42. For acrylic material at the
pressure 1.0 bar the tensile strength
Table 8: Percentage contribution of
is 40.9 Mpa. Further increase of
Process Parameter for tensile strength for
pressure 2.0 bar the tensile strength abs material
is also increases at 41.1Mpa. At the
Sources of Percentage
pressure 4.5 bar the tensile strength
Contribution
Variation
RRTT
is suddenly increases 47.0 Mpa. At
(%)
the last point pressure 5.0 bar the
Factor – A Weld time 52.10
IIJJEE

tensile strength is decreases at 45.6

Mpa. For polycarbonate also when Factor – B Pressure 38.49
we increase the pressure gradually
Error 9.4073
the tensile strength is also increase.
Total 100
Here at last 2 point the tensile
strength of polycarbonate material is
Table 9: Percentage contribution of
decreases like acrylic and abs
Process Parameter for tensile strength for
material due to overheating in the acrylic material
welding.
Sources of Percentage
As per ANOVA Analysis we can find the Contribution
Variation
percentage contribution of input parameters (%)
for Tensile strength for ABS, Acrylic and
polycarbonate material is as shown in below Factor – A Weld time 84.013
Tables.
Factor – B Pressure 14.16

www.ijert.org 8
 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
Vol. 2 Issue 3, March - 2013

Error 1.818 confirmed that the weld time is

most effective factor in
Total 100
comparison of pressure for same
welding condition.
Table 10: Percentage contribution of
Process Parameter for tensile strength for (3) The other analysis we judge from
polycarbonate material our experimental work is the

8.0 Conclusions: weld ability of the Acrlonitrile

butadiene (abs), is more than the
With the above study on ultrasonic plastic
welding the tensile strength conclusion of acrylic and polycarbonate
the welding can be drawn as follows: material.
9.0 References:

 The weld time is most significant

1. Michael.J.Troughton Hand book of
control factor on Tensile strength plastic joining: A practical guide,
during ultrasonic plastic welding. Page: 25,26,31,32.
RRTT
Meanwhile the pressure is also
2. Jiromaru Tsujino, Takako Uchida,
equally significant. The Katsuhisa Yamano Noriyuki
IIJJEE

recommended parametric Iwamoto, Tesugi Uveoka., welding

characteristics of ultrasonic plastic
combination for maximum tensile
welding using two-vibration system
strength of the material. of 90 KHz and 27 or 20 KHz and
 On the basic of the experimental complex vibration
results, Analysis of variance (Anova) system,2004,Page67-74.

and the effect of welding parameters 3. Dr Ying Ming,Prof Ling Shih Fu, Dr
on tensile strength the conclusion Sun Zheng ,A New Optimization
can be drawn for effective welding Method for Horn Designs in
Ultrasonic Welding Systems,2002.
of Abs, Acrylic and polycarbonate
materials by ultrasonic plastic 4. Shin-ichi-Matsuoka, Ultrasonic
welding processes as follows: Welding and characteristics of glass-
fibre reinforced plastic: Comparison
(1) Increasing the weld time the
between the paper-making method
tensile strength is improved. and the impregnation method.
(2) For time based ultrasonic plastic 16, January, 1995, page:427-431.
welding machine it was

www.ijert.org 9
 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
Vol. 2 Issue 3, March - 2013

5. Jiromaru Tsujino, Misugi

Hongoh,Masafumi
Yoshikuni,Hidekazu Hashii, Tetsugi
Ueoka, Welding characteristics of
27,40,and 67 KHz ultrasonic plastic
welding system using fundamental-
and higher-resonance
frequencies.,2004,Page:131-137.

6. Yi Luo,Zongbo Zhang,Xiaodong
Wang, Yingsong Zheng, Ultrasonic
bonding for thermoplastic
microfluidic devices without energy
director, 2010,2429-2436.

7. Avarahum Benatar, plastics and

composites welding hand
book.volume 10,
RRTT
8. I.V.Mojgovi, ultrasonic welding
processes.2006, 225-230.
IIJJEE

9. Tolunay, Heating and bonding

mechanism of ultrasonic welding of
thermoplastic.2003, Page:726-733.

10. Mozgovi, I.V., and Samchel,

Ultrasonic welding of
Polymethacrylate with preliminary
surface preparation, 2003, page:106-
108.

www.ijert.org 10