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In Vibration welding, two plastic parts are in frictional contact with each other with certain frequency, amplitude and pressure. As a result of the friction between both parts heat is generated which causes the polymer to melt at the interface. Due to pressure, the molten polymer flows out of the weld zone giving rise to flash. After the vibration has stopped the layer of polymer melt solidifies and a joint I generated.
Tooling is application-specific and will need to be designed uniquely for each program. It is therefore highly recommended that the tooling be planned along with the part design, so that feasibility is covered from the start.
The function of the welding tool is to provide constant, uniform pressure across the weld joint and to ensure that the parts sense the uniform relative amplitude generated by the welding machine. In order to satisfy these requirements, the tooling must be able to rigidly support the entire weld joint, either through direct contact with the welding flange geometry or by transmission of the pressure through structural portions of the shell geometry itself.
Well-designed tooling consists of an upper tool that is mounted to the vibration head and a lower tool that is mounted to the lifting table. The parts are placed into the fixturing details of the tool at the start of each cycle.
Tooling construction typically consists of hardened steel segments that are CNC cut to the part shape. These details may be on moving tool actions in the lower tool only. The upper tool cannot have any tool actions,as the forces imposed during the process would cause the tool to fail. It is important to understand these points for part design so that access to the weld joint on the part upper shell can be planned without tool actions.
An improper tool design that does not provide constant, uniform pressure across the weld joint or allows the parts to slip relative to each other, thereby not providing the uniform relative amplitude, will result in a loss of process control and the production of nonconforming parts.
Joint designs : Butt(A). Butt with U-Flange (B), Tongue and groove with U-Flange (C). Double tongue and groov (D)
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