Intshayelelo
Ngophuhliso lwe-teknoloji ye-ultrasonic, ukusetyenziswa kwayo kuninzi kwaye kuninzi, kungasetyenziselwa ukucoca iincinci ezincinci, kwaye kunokusetyenziselwa ukuhambisa isinyithi okanye iplastiki. Ngokukodwa kwiimveliso zeplastiki zanamhlanje, i-welding ye-ultrasonic isetyenziswa kakhulu, kuba isakhiwo se-screw asishiywanga, ukubonakala kungagqibelela ngakumbi, kwaye umsebenzi wokungena kwamanzi kunye nokukhuselwa uthuli kuyafumaneka. Uyilo lophondo lweplastikhi lwewelding lunefuthe elibalulekileyo kumgangatho wokugqibela we-welding kunye namandla emveliso. Kwimveliso yeemitha zombane ezintsha, amaza e-ultrasonic asetyenziselwa ukudibanisa ubuso obuphezulu kunye nobezantsi kunye. Nangona kunjalo, ngexesha lokusetyenziswa, kufunyenwe ukuba ezinye izixhobo zifakwe kumatshini kwaye zaqhekeka kwaye ezinye iintsilelo zenzeka ngexesha elifutshane. Ezinye izixhobo zokuwelda izixhobo Umgangatho wesiphene uphezulu. Iimpazamo ezahlukeneyo zibe nefuthe elibonakalayo kwimveliso. Ngokwengqiqo, abathengisi bezixhobo banobuchule obunqabileyo bokuyila izixhobo, kwaye rhoqo ngokulungiswa okuphindaphindiweyo ukufezekisa izikhombisi zoyilo. Ke ngoko, kubalulekile ukuba sisebenzise izibonelelo zethu zobuchwephesha ekuphuhliseni izixhobo ezomeleleyo kunye nendlela efanelekileyo yoyilo.
2 Umgaqo we-Ultrasonic welding
I-Ultrasonic welding yeplastikhi yindlela yokulungisa esebenzisa indibaniselwano ye-thermoplastics kwisantya esinyanzelekileyo sokungcangcazela, kunye neendawo zokuwelda ezirhuqwayo ngokuchasene ukuze zivelise ubushushu obuphezulu bendawo. Ukulungiselela ukufezekisa iziphumo ezilungileyo ze-ultrasonic welding, izixhobo, izixhobo kunye neeparameter zenkqubo ziyafuneka. Oku kulandelayo yintshayelelo emfutshane kumgaqo wayo.
2.1 Inkqubo ye-Ultrasonic welding
Umzobo 1 ngumbono wesikim wenkqubo ye-welding. Amandla ombane agqithiselwa kumvelisi wesiginali kunye nesikhulisi samandla ukuvelisa isibonisi esitshintshayo sombane se-ultrasonic frequency (> 20 kHz) esetyenziswa kwi-transducer (piezoelectric ceramic). Ngokusebenzisa i-transducer, amandla ombane aba ngamandla ombane wokungcangcazela, kunye nobungakanani bentshukumo yoomatshini buhlengahlengiswa luphondo kwindawo efanelekileyo yokusebenza, kwaye emva koko idluliselwe ngokufanayo kwizinto ezidibene nayo ngentloko yesixhobo (welding izixhobo). Iindawo zonxibelelwano zezi zixhobo zimbini zewelding zixhomekeke kunyikima okunyanzelekileyo okuphezulu, kwaye ubushushu bokukhuhlana bubangela ukunyibilika kobushushu obuphezulu. Emva kokupholisa, izinto zidityanisiwe ukufezekisa iwelding.

Kwinkqubo yokuwelda, umthombo wesiginali yinxalenye yesekethe equlathe isandisi sesikhulisi samandla ozinzo lwalo rhoqo kunye namandla okuqhuba okuchaphazela ukusebenza komatshini. Izinto eziphathekayo ziyi-thermoplastic, kwaye ukuyila kwendawo edibeneyo kufuneka iqwalasele indlela yokukhawuleza ukukhupha ubushushu kunye nedokodo. Izitshintshi, iimpondo kunye neentloko zezixhobo zonke zinokuthathelwa ingqalelo kulwakhiwo lomatshini kuhlalutyo olulula lokudibanisa ukungcangcazela kwabo. Kwi-welding yeplastiki, ukungcangcazela komatshini kudluliswa ngohlobo lwamaza akude. Ungawadlulisa njani amandla kwaye uhlengahlengise i-amplitude yeyona nto iphambili kuyilo.
2.2 Intloko yesixhobo (izixhobo zentsimbi)
Isixhobo sentloko sisebenza njengonxibelelwano phakathi komatshini we-ultrasonic welding kunye nezinto. Owona msebenzi uphambili kukuhambisa ukungcangcazela koomatshini okukhutshelwa ngumahluko ngokulinganayo nangokufanelekileyo kwimathiriyeli. Izinto ezisetyenzisiweyo zihlala zikumgangatho ophezulu wealuminium alloy okanye ingxubevange ye-titanium. Ngenxa yokuba uyilo lwezixhobo zeplastiki lutshintsha kakhulu, inkangeleko yahluke kakhulu, kwaye intloko yesixhobo kufuneka itshintshe ngokufanelekileyo. Ubume bendawo yokusebenza kufuneka buhambelane kakuhle nezinto eziphathekayo, ukuze kungonakalisi iplastiki xa kushukunyiswa; Kwangelo xesha, i-odolo yokuqala yokungcangcazela kwexesha elide kufuneka ilungelelaniswe nesiphumo sokukhutshwa komatshini wokudibanisa, kungenjalo amandla ombane aya kusetyenziswa ngaphakathi. Xa intloko yesixhobo ingcangcazela, uxinzelelo lwasekhaya lwenzeka. Ungalusebenzisa njani olu lwakhiwo lwasekhaya ikwayiqwalaselo loyilo. Eli nqaku liphonononga indlela yokufaka iintloko zezixhobo zoyilo ukulungiselela ukuphucula iiparameter zoyilo kunye nokunyamezelana kwemveliso
Uyilo lwezixhobo ze-3 ze-welding
Njengoko bekutshiwo ngaphambili, uyilo lwezixhobo ze-welding kubaluleke kakhulu. Baninzi abathengisi bezixhobo ze-ultrasonic eTshayina ezivelisa ezabo izixhobo zokuwelda, kodwa uninzi lwazo zizinto zokulinganisa, kwaye zihlala zisika kwaye zivavanya. Ngale ndlela yohlengahlengiso iphindaphindwayo, ulungelelwaniso lwezixhobo kunye nezixhobo ezihamba rhoqo ziyafezekiswa. Kweli phepha, indlela enesiphelo ingasetyenziselwa ukumisela ubungakanani bexesha xa kuyilwa isixhobo. Iziphumo zovavanyo lwezixhobo kunye nempazamo yokuyila ziipesenti ezi-1 kuphela. Kwangelo xesha, eli phepha lazisa umxholo we-DFSS (Uyilo lweSithupha Sigma) yokwandisa kunye noyilo olomeleleyo lwezixhobo. Umxholo woyilo lwe-6-Sigma kukuqokelela ngokupheleleyo ilizwi lomthengi kwinkqubo yoyilo loyilo ekujoliswe kulo; kunye nokuqwalaselwa kwangaphambili kokuphambuka okunokwenzeka kwinkqubo yemveliso ukuqinisekisa ukuba umgangatho wemveliso yokugqibela uhanjiswa kwinqanaba elifanelekileyo. Inkqubo yoyilo ibonisiwe kuMzobo 2. Ukuqala kuphuhliso lwezikhombisi zoyilo, ubume kunye nemilinganiselo yezixhobo ekuqaleni ziyilelwe ngokwamava akhoyo. Imodeli yeparametric isekwe kwi-ANSYS, emva koko imodeli imiselwe yindlela yokulinganisa yoyilo (DOE). Iiparameter ezibalulekileyo, ngokweemfuno eziqinileyo, ukumisela ixabiso, emva koko usebenzise indlela engaphantsi kwengxaki yokwandisa ezinye iiparameter. Ukuthathela ingqalelo impembelelo yezixhobo kunye neeparamitha zokusingqongileyo ngexesha lokwenziwa nokusetyenziswa kwesixhobo, ikwayilelwe kunye nokunyamezelana ukuhlangabezana neemfuno zeendleko zokuvelisa. Okokugqibela, ukuveliswa, ukuvavanywa kunye novavanyo loyilo lwethiyori kunye nempazamo yokwenyani, ukuhlangabezana nezalathi zoyilo ezithunyelwayo. Eli nyathelo ngenyathelo ngenyathelo intshayelelo.
3.1 Uyilo lweemilo zejiyometri (ukuseka imodeli yeparametric)
Ukuyila isixhobo se-welding kuqala kumisela ubume bejometri kunye nolwakhiwo kwaye kuseka imodeli yeparametric yohlalutyo olulandelayo. Umzobo 3 a) uyilo lwesixhobo esisesona sixhobo sixhaphakileyo, apho kuvulwa inani lemijelo emise okwe-U kwicala lokungcangcazela kwinto emalunga ne-cuboid. Ubungakanani ngokubanzi bubude bemiyalelo ye-X, Y, kunye ne-Z, kwaye ubukhulu be-X kunye no-Y ngokuthelekiswa ngokubanzi kuthelekiswa nobungakanani bento yokusebenza edityanisiweyo. Ubude be-Z bulingana nesiqingatha samaza e-ultrasonic wave, kuba kwithiyori yokungcangcazela yeklasikhi, i-odolo yokuqala yokuhamba kwe-axial yento edibeneyo imiselwe bubude bayo, kwaye ubude besiqingatha somtshangatshangiso bulingana ngqo ne-acoustic Ukuhamba rhoqo kwamaza. Olu luyilo lwandisiwe. Sebenzisa, kuluncedo ekusasazeni amaza esandi. Injongo yendawo emise okwe-U kukunciphisa ilahleko yokungcangcazela kwangoko kwesixhobo. Indawo, ubungakanani kunye nenombolo zichongiwe ngokobungakanani besixhobo sonke. Kuyabonakala ukuba kuyilo, kukho iiparameter ezimbalwa ezinokulawulwa ngokukhululekileyo, ngenxa yoko senze uphuculo kwesi siseko. Umzobo 3 b) sisixhobo esisandula ukuyilwa esineeparamitha zesayizi enye kunoyilo lwesiqhelo: irediyasi yangaphandle ye-arc R. Ukongeza, umjelo ukrolwe kumphezulu wokusebenza kwesixhobo sokusebenzisana nomphezulu womsebenzi weplastiki, eliluncedo lokuhambisa amandla ombane kunye nokukhusela indawo yokusebenza kumonakalo. Le modeli ihlala imodareyithwa kwi-ANSYS, emva koko kuyilo olulandelayo lokulinga.
Uyilo lovavanyo lwe-Do2 3.2 (ukumiselwa kweeparameter ezibalulekileyo)
I-DFSS yenzelwe ukusombulula iingxaki zobunjineli. Ayilandeli ukugqibelela, kodwa iyasebenza kwaye yomelele. Ibandakanya umbono we-6-Sigma, ibambe eyona nto iphikisanayo, kwaye ishiye i "99.97%", ngelixa ifuna uyilo ukuba lukwazi ukumelana nokwahluka kokusingqongileyo. Ke ngoko, ngaphambi kokwenza i parameter isebenze, kufuneka ihlolwe kuqala, kwaye ubungakanani obunefuthe elibalulekileyo kulwakhiwo kufuneka lukhethwe, kwaye amaxabiso abo kufuneka amiselwe ngokomgaqo wokuqina.
Ukucwangciswa kweparameter ye-DOE kunye ne-DOE
Iiparamitha zoyilo bubume bezixhobo kunye nobungakanani bemeko yendawo emise okwe-U, njl njl. Ipharamitha ekujoliswe kuyo yinkqubo yokuqala yokuhamba kwe-axial vibration frequency kuba ineyona mpembelelo inkulu kwi-weld, kwaye ubuninzi boxinzelelo oluxineneyo kunye nomehluko kubungakanani bomhlaba osebenzayo bunqunyelwe njengezinto eziguquguqukayo zikarhulumente. Ngokusekwe kumava, kucingelwa ukuba isiphumo seeparameter kwiziphumo silayini, ke into nganye isetelwe kumanqanaba amabini, aphezulu kunye asezantsi. Uluhlu lweeparameter kunye namagama ahambelana ngolu hlobo lulandelayo.
I-DOE yenziwa kwi-ANSYS isebenzisa imodeli yeparametric esekwe ngaphambili. Ngenxa yokulinganiselwa kwesoftware, i-DOE epheleleyo inokusebenzisa kuphela ukuya kwiiparamitha ezisi-7, ngelixa imodeli ineeparameter ezisi-8, kunye nohlalutyo lwe-ANSYS lweziphumo ze-DOE alunabunzulu njengesoftware ye-6-sigma, kwaye ayinakho ukuphatha ukudibana. Ke ngoko, sisebenzisa i-APDL ukubhala iluphu ye-DOE ukubala kunye nokukhupha iziphumo zenkqubo, emva koko sibeke idatha kwiMinitab yohlalutyo.
3.2.2 Uhlalutyo lweziphumo ze-DOE
Uhlalutyo lwe-DoE lweMinitab lubonakalisiwe kuMzobo 4 kwaye kubandakanya eyona nto iphambili kuhlalutyo lwezinto kunye nohlalutyo lokunxibelelana. Olona hlalutyo luphembelelayo lusetyenziselwa ukumisela ukuba loluphi utshintsho olwenziweyo olunefuthe elikhulu kuguquguquko ekujoliswe kulo, ngaloo ndlela lubonisa ukuba zeziphi izinto ezifunekayo zoyilo. Ukudibana phakathi kwezinto emva koko kuhlahlelwa ukumisela inqanaba lezinto kunye nokunciphisa inqanaba lokudibana phakathi kokuguquguqukayo koyilo. Thelekisa inqanaba lotshintsho lwezinye izinto xa uyilo luphezulu okanye luphantsi. Ngokwe-axiom ezimeleyo, uyilo olugqibeleleyo aluhambelani omnye nomnye, ke khetha inqanaba elingafaniyo.
Iziphumo zohlalutyo lwesixhobo se-welding kweli phepha zezi: iiparameter zoyilo ezibalulekileyo zi-arc radius engaphandle kunye nobubanzi be-slot yesixhobo. Inqanaba leeparamitha zombini "liphezulu", oko kukuthi, irediyasi ithatha ixabiso elikhulu kwi-DOE, kwaye ububanzi be-groove buthatha nexabiso elikhulu. Iiparameter ezibalulekileyo kunye nexabiso lazo zagqitywa, emva koko kwasetyenziswa ezinye iiparameter ukwandisa uyilo kwi-ANSYS ukulungelelanisa izixhobo ezihamba rhoqo ukuze zitshatise ukusebenza rhoqo kumatshini wokudibanisa. Inkqubo yokwenziwa koku kulandelayo
Ukulungiswa kweparameter ye3.
Iisetingi zeparameter yoyilo loyilo ziyafana nezo ze-DOE. Umahluko kukuba amaxabiso eeparameter ezimbini ezibalulekileyo amiselwe, kwaye ezinye iiparameter ezintathu zinxulumene nepropathi yezinto, ezithathwa njengengxolo kwaye zingenakulungiswa. Iiparameter ezintathu ezishiyekileyo ezinokuhlengahlengiswa yindawo ye-axial yesakhiwo, ubude kunye nobubanzi besixhobo. Ukulungiselela kusetyenziswa indlela yokulinganisa esisiseko kwi-ANSYS, eyindlela esetyenziswa ngokubanzi kwiingxaki zobunjineli, kwaye inkqubo ethile ishiyiwe.
Kubalulekile ukuba uqaphele ukuba ukusebenzisa rhoqo njengokwahluka ekujolise kuko kufuna isakhono esincinci ekusebenzeni. Kuba zininzi iiparameter zoyilo kunye noluhlu olwahlukileyo lokwahluka, iindlela zentshukumo yezixhobo zininzi kuluhlu lwamaxesha omdla. Ukuba iziphumo zohlalutyo lweemodyuli zisetyenziswa ngokuthe ngqo, kunzima ukufumana iodolo yokuqala yendlela ye-axial, kuba ukulandelelana kwemodyuli ngokulandelelana kunokwenzeka xa iiparameter zitshintsha, oko kukuthi, ubukhulu bendalo obuqhelekileyo obuhambelana notshintsho lwimo yoqobo. Ke ngoko, eli phepha lamkela uhlalutyo lweemodyuli kuqala, lize emva koko lisebenzise indlela yokumisela imo yokufumana impendulo kwigophe. Ngokufumana ixabiso lokuphakama kwempendulo yempendulo, inokuqinisekisa ukuba imodyuli ehambelana nayo. Oku kubaluleke kakhulu kwinkqubo yokusebenza okuzenzekelayo, ishenxisa isidingo sokumisela ngesandla imeko.
Emva kokuba ukwenziwa kugqityiwe, ukusebenza kokuyilwa kwesixhobo kunokuba kufutshane kakhulu nokujoliswa kwithagethi, kwaye impazamo ingaphantsi kwexabiso lokunyamezelana elichazwe ekusebenziseni. Okwangoku, uyilo lwezixhobo lumiselwe ngokusisiseko, lulandelwa kukunyamezelana kwemveliso kuyilo lwemveliso.
3.4 uyilo lokunyamezelana
Uyilo lolwakhiwo ngokubanzi lugqityiwe emva kokuba zonke iiparameter zoyilo zimiselwe, kodwa kwiingxaki zobunjineli, ngakumbi xa kuthathelwa ingqalelo indleko zemveliso ngobuninzi, uyilo lonyamezelo lubalulekile. Ixabiso lokuchaneka okuphantsi nalo liyancitshiswa, kodwa amandla okuhlangabezana neemetwork zoyilo afuna ukubalwa kweenkcukacha manani. Inkqubo yoYilo lwePDS kwi-ANSYS inokuhlalutya ngcono ubudlelwane phakathi kokunyamezelana kweparameter yoyilo kunye nokunyamezelwa kweparameter, kwaye inokuvelisa iifayile ezinxulumene ngokupheleleyo.
3.4.1 iisetingi zePDS kunye nokubala
Ngokwengcinga ye-DFSS, uhlalutyo lokunyamezelana kufuneka lwenziwe kwiiparameter zoyilo ezibalulekileyo, kunye nokunye ukunyamezelana ngokubanzi kunokumiselwa ngokwamandla. Imeko ekweli phepha ikhetheke ngokukodwa, kuba ngokwamandla okuchola, ukunyamezelana kwemveliso kweeparameter zoyilo lwejometri kuncinci kakhulu, kwaye kunefuthe elincinci kumaza esixhobo sokugqibela; Ngelixa iiparameter zemathiriyeli ekrwada zahluke kakhulu ngenxa yabanikezeli, kunye nexabiso lezinto ezisetyenziswayo ezingaphezulu kwama-80% eendleko zokwenza izixhobo. Ke ngoko, kubalulekile ukuseta uluhlu lokunyamezelana lweepropathi zezinto eziphathekayo. Iimpawu ezifanelekileyo zepropathi apha luxinano, imodyuli yokuqina kunye nesantya sokusasazeka kwesandi.
Uhlalutyo lokunyamezelana lusebenzisa ukulinganisa okungahleliwe kweMonte Carlo kwi-ANSYS ukwenza isampulu yendlela yesiLatin Hypercube kuba inokwenza ukuhanjiswa kwamanqaku okulinganisa kube kufana kwaye kufanelekile, kwaye ufumane ulungelelwaniso olungcono ngamanqaku ambalwa. Eli phepha liseta amanqaku angama-30. Thatha ukuba unyamezelo lweeparitha ezintathu zezinto zihanjiswa ngokweGauss, ekuqaleni zinikwe umda ophezulu nowezantsi, emva koko zibalwe kwi-ANSYS.
3.4.2 Uhlalutyo lweziphumo zePDS
Ngokubalwa kwe-PDS, amaxabiso aguqulweyo ekujolise kuwo ahambelana namanqaku esampulu angama-30 anikiwe. Ukuhanjiswa kwezinto ezijolise kuko akaziwa. Iiparamitha ziphinde zafakwa kwakhona kusetyenziswa isoftware yeMinitab, kwaye amaza asasazwa ngokusasazwa kuhambiso oluqhelekileyo. Oku kuqinisekisa ithiyori yamanani ohlalutyo lokunyamezelana.
Ukubala kwe-PDS kunika ifomula efanelekileyo ukusuka kuyilo oluguqukayo ukuya kulwandiso lokonyuka kojoliso ekujolise kulo: apho y kukungafani kokujolise kuko, x kukwahluka kuyilo, c kukulingana kokudibana, kwaye i linani eliguqukayo.

Ngokwangoku, unyamezelo ekujoliswe kulo lunokwabelwa uyilo ngalunye ukugqibezela umsebenzi woyilo lokunyamezelana.
3.5 Ukuvavanywa kokuvavanywa
Inxalenye engaphambili yinkqubo yoyilo lwesixhobo sonke se-welding. Emva kokugqitywa, izinto eziluhlaza zithengwa ngokungqinelana nezinto ezivumeleke kuyilo, emva koko zisiwe kwimveliso. Ukuvavanywa rhoqo kunye novavanyo lwenziwa emva kokuba kugqityiwe ukwenziwa, kwaye indlela yovavanyo esetyenzisiweyo yeyona ndlela ilula kwaye isebenzayo yovavanyo lwe-sniper. Ngenxa yokuba isalathiso esona sixhalabisayo kukuyalelwa kwe-axial modal frequency frequency, isivamvo sokukhawulezisa siqhotyoshelwe kwindawo yokusebenza, kwaye elinye icala libethelwa kwicala le-axial, kwaye eyona frequency yezixhobo inokufunyanwa ngohlalutyo lwembonakalo. Iziphumo zokulinganisa zoyilo zi-14925 Hz, iziphumo zovavanyo yi-14954 Hz, isisombululo sokuhamba rhoqo yi-16 Hz, kwaye eyona mpazamo iphantsi kwe-1%. Kuyabonakala ukuba ukuchaneka kwento yokulinganisa yokulinganisa kubalo lweemodyuli kuphezulu kakhulu.
Emva kokuphumelela kuvavanyo lokulinga, isixhobo sokwenza izixhobo sifakwa kwimveliso nakwindibano kumatshini we-ultrasonic welding. Isimo sokuphendula silungile. Umsebenzi uzinzile ngaphezulu kwesiqingatha sonyaka, kwaye inqanaba lokufumana iwelding liphezulu, elidlule kubomi beenkonzo zeenyanga ezintathu obuthembiswe ngumenzi wezixhobo ngokubanzi. Oku kubonisa ukuba uyilo luyimpumelelo, kwaye inkqubo yokuvelisa ayitshintshwanga iphindaphindwe kwaye ihlengahlengiswe, ukugcina ixesha kunye namandla.
4 Isiphelo
Eli phepha liqala ngomgaqo wokufakelwa kweplastikhi ye-ultrasonic, ubamba nzulu ukugxila kwezobuchwephesha kwe-welding, kwaye uphakamisa umbono woyilo lwezixhobo ezitsha. Emva koko sebenzisa umsebenzi wokulinganisa onamandla wezinto ezigqityiweyo ukuhlalutya uyilo ngokuchanekileyo, kwaye wazise umbono we-6-Sigma yoyilo lwe-DFSS, kwaye ulawule iiparameter zoyilo ezibalulekileyo ngoyilo lovavanyo lwe-ANSYS DoE kunye nohlalutyo lokunyamezelana lwe-PDS ukufezekisa uyilo olomeleleyo. Okokugqibela, izixhobo zenziwa ngempumelelo kube kanye, kwaye uyilo lwalunengqiqo kuvavanyo lokuvavanywa rhoqo kunye nokuqinisekiswa kwemveliso eyiyo. Ikwangqina ukuba le seti yeendlela zoyilo zinokwenzeka kwaye zisebenza.