How to design the welding fusion line for welding items before using an ultrasonic welding machine?
Time:03/11/2024    Views:1  
Before using an ultrasonic welding machine, designing the welding fusion line of the welded item is a crucial step that directly affects the quality and effectiveness of welding. Here are some suggestions to help you design a reasonable welding fusion line:

1. Determine the type of material: Firstly, it is necessary to clarify the type of material used for welding the item. Different materials have different melting points and physical properties, so it is necessary to design fusion lines for specific materials. For example, for materials such as PS, AS, ABS, acrylic, and Norilu, the typical welding fusion design may be 0.3mm, while for watertight or airtight welding, the fusion design may need to be increased to 0.5mm. For crystalline materials such as high-density PE, Nilon, PP, plastic copper, PC, PBT, etc., the typical fusion line design may be 0.5mm, while in watertight or airtight welding, a fusion line of 0.8mm may be required.

2. Consider welding requirements: Determine the height and shape of the fusion line based on the functional requirements of the welded item. For example, if the welded item needs to meet the requirements of water tightness or air tightness, the height of the fusion line should be around 0.5-0.8mm. However, please note that the height and shape of the fusion line also need to be designed according to the wall thickness of the product to ensure the best welding effect.

3. Choose the appropriate fusion method: There are various fusion methods for ultrasonic welding machines, such as oblique cutting, step tip, peak valley tip, etc. Different methods are suitable for different materials and products. For example, the oblique cut type is suitable for welding water tightness and large products, and it is better to fuse the wire between 0.3-0.8mm; The stepped tip type is suitable for welding with water tightness and preventing protrusion or cracking, and the fusion wire is more suitable in the range of 0.3-0.8mm; The peak valley pointed type is suitable for water tight and high-strength welding, and the fusion wire is more appropriate in the range of 0.3-0.6mm.

4. Optimize structural design: Reasonable ultrasonic plastic structural design is crucial for welding processes. When designing a fusion line, it is important to ensure that the initial contact area between the two plastic parts is small enough to concentrate energy and reduce the overall energy required for plastic melting and fusion. This helps to avoid the occurrence of virtual welding, shorten welding time, and improve welding quality.

In summary, designing welding fusion lines is a process that requires comprehensive consideration based on specific materials, welding requirements, and product structure. Through reasonable fusion line design, it can be ensured that the ultrasonic welding machine achieves the best welding effect during use.

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