Presenting the Traction-Separation Law for Ultrasonic Welding of Glass-Fiber Reinforced Polypropylene Composite

Document Type : Research Article

Authors

1 Department of Mechanical Engineering, University of Tabriz, Tabriz, Iran

2 Department of Mechanical Engineering, University of Tabriz

Abstract

The generalized progressive damage model is numerically and experimentally studied to predict the degradation process in end notch flexure composite specimens welded by the ultrasonic method. In numerical modeling, a trapezoidal traction-separation model that expresses the embedded process zone is developed using three data reduction methods of the compliance calibration method, classical beam theory, and compliance-based beam method, and formulated by combining failure and damage mechanics. Finally, the force-displacement diagrams obtained from experimental investigations and the force-displacement diagrams extracted from numerical modeling are compared. The results demonstrate that the models extracted using the compliance-based beam method and classical beam theory method make accurate predictions compared to the compliance calibration method.

Keywords

Main Subjects


[1] R.E.e. Shalin, Polymer matrix composites, Springer Science & Business Media, 2012.
[2] J. Comyn, Adhesion Science, Royal Society of Chemistry, 2007.
 [3]D. Brassard, M. Dubé, J.R. Tavares, Resistance welding of thermoplastic composites with a nanocomposite heating element, Composites Part B: Engineering, 165 (2019) 779-784.
[4] I.F. Villegas, L. Moser, A. Yousefpour, P. Mitschang, H.E. Bersee, Process and performance evaluation of ultrasonic, induction and resistance welding of advanced thermoplastic composites, Journal of Thermoplastic Composite Materials, 26(8) (2013) 1007-1024.
[5] D. Stavrov, H. Bersee, Resistance welding of thermoplastic composites-an overview, Composites Part A: Applied Science and Manufacturing, 36(1) (2005) 39-54.
[6] B. Vijendra, A. Sharma, Induction heated tool assisted friction-stir welding (i-FSW): A novel hybrid process for joining of thermoplastics, Journal of Manufacturing Processes, 20 (2015) 234-244.
 [7]S. Pappadà, A. Salomi, J. Montanaro, A. Passaro, A. Caruso, A. Maffezzoli, Fabrication of a thermoplastic matrix composite stiffened panel by induction welding, Aerospace Science and Technology, 43 (2015) 314-320.
[8] M. Troughton, Chapter 11—Induction Welding, Handbook of Plastics Joining, 2nd ed.; William Andrew Publishing: Boston, MA, USA,  (2009) 113-120.
[9] T. Ahmed, D. Stavrov, H. Bersee, A. Beukers, Induction welding of thermoplastic composites—an overview, Composites Part A: Applied Science and Manufacturing, 37(10) (2006) 1638-1651.
[10] S. Mahdi, H.-J. Kim, B. Gama, S. Yarlagadda, J. Gillespie Jr, A comparison of oven-cured and induction-cured adhesively bonded composite joints, Journal of composite materials, 37(6) (2003) 519-542.
[11] W. Tao, X. Su, H. Wang, Z. Zhang, H. Li, J. Chen, Influence mechanism of welding time and energy director to the thermoplastic composite joints by ultrasonic welding, Journal of manufacturing processes, 37 (2019) 196-202.
[12] A. Benatar, Ultrasonic welding of plastics and polymeric composites, in:  Power Ultrasonics, Elsevier, (2015) 295-312.
[13] K. Goto, K. Imai, M. Arai, T. Ishikawa, Shear and tensile joint strengths of carbon fiber-reinforced thermoplastics using ultrasonic welding, Composites Part A: Applied Science and Manufacturing, 116 (2019) 126-137.
[14] P. Ochôa, I.F. Villegas, R.M. Groves, R. Benedictus, Diagnostic of manufacturing defects in ultrasonically welded thermoplastic composite joints using ultrasonic guided waves, NDT & E International, 107 (2019) 102126.
[15] S.F. Raza, Ultrasonic welding of thermoplastics, University of Sheffield, (2015.(
[16] S. Mostafavi, D.F. Hesser, B. Markert, Effect of process parameters on the interface temperature in ultrasonic aluminum wire bonding, Journal of Manufacturing Processes, 36 (2018) 104-114.
[17] Y.-H. Gao, Q. Zhi, L. Lu, Z.-X. Liu, P.-C. Wang, Ultrasonic Welding of Carbon Fiber Reinforced Nylon 66 Composite Without Energy Director, Journal of Manufacturing Science and Engineering, 140(5) (2018) 051009.
[18] T. Chinnadurai, S. Arungalai Vendan, C. Rusu, E. Scutelnicu, Experimental Investigations on the Polypropylene Behavior during Ultrasonic Welding, Materials and Manufacturing Processes, 33(7) (2018) 718-726.
[19] I.F. Villegas, G. Palardy, Ultrasonic Welding of Thermoplastic Composite Coupons for Mechanical Characterization of Welded Joints through Single Lap Shear Testing, Journal of visualized experiments: JoVE,  108 (2016) e53592.
[20] N. Sîrbu, O. Oancă, Optimizing ultrasonic joining technologies of composite polymer materials, (2016) 25:9-13.
[21] I.F. Villegas, Strength development versus process data in ultrasonic welding of thermoplastic composites with flat energy directors and its application to the definition of optimum processing parameters, Composites Part A: Applied Science and Manufacturing, 65 (2014) 27-37.
[22] R. Nikoi, M. Sheikhi, N.B.M. Arab, Experimental Analysis of Effects of Ultrasonic Welding on Weld Strength of Polypropylene Composite Samples, International Journal of Engineering-Transactions C: Aspects, 28(3) (2014) 447.
[23] F. Balle, G. Wagner, D. Eifler, Ultrasonic Metal Welding of Aluminium Sheets to Carbon Fibre Reinforced Thermoplastic Composites, Advanced Engineering Materials, 11(1‐2) (2009) 35-39.
[24] F. Balle, G. Wagner, D. Eifler, Ultrasonic Spot Welding of Aluminum Sheet/Carbon Fiber Reinforced Polymer–Joints, Material Science and Engineering Technology, 38(11) (2007) 934-938.
[25] S. Krüger, G. Wagner, D. Eifler, Ultrasonic Welding of Metal/Composite Joints, Advanced Engineering Materials, 6(3) (2004) 157-159.
[26] S. Hashemi, A. Kinloch, J. Williams, The effects of geometry, rate and temperature on the mode I, mode II and mixed-mode I/II interlaminar fracture of carbon-fibre/poly (ether-ether ketone) composites, Journal of Composite Materials, 24(9) (1990) 918-956.
[27] T. Lyashenko‐Miller, G. Marom, Delamination fracture toughness of UHMWPE fibers/polyurethane laminates interleaved with carbon nanotube‐reinforced polyurethane films, Polymers for Advanced Technologies, 28(5) (2017) 606-612.
[28] A. Arrese, N. Insausti, F. Mujika, M. Perez-Galmés, J. Renart, A novel experimental procedure to determine the cohesive law in ENF tests, Composites Science and Technology, 170 (2019) 42-50.
[29] X. Lu, M. Ridha, B. Chen, V. Tan, T. Tay, On cohesive element parameters and delamination modelling, Engineering Fracture Mechanics, 206 (2019) 278-296.
[30] J.D. Whitcomb, Analysis of instability-related growth of a through-width delamination, National Aeronautics and Space Administration, Langley Research Center, 1984.
[31] B.D. Davidson, X. Sun, Effects of friction, geometry, and fixture compliance on the perceived toughness from three-and four-point bend end-notched flexure tests, Journal of reinforced plastics and composites, 24(15) (2005) 1611-1628.
[32] M. De Moura, A. De Morais, Equivalent Crack Based Analyses of ENF and ELS Tests, Engineering Fracture Mechanics, 75(9) (2008) 2584-2596.
[33] M. De Moura, R. Campilho, J. Gonçalves, Pure mode II fracture characterization of composite bonded joints, International Journal of Solids and Structures, 46(6) (2009) 1589-1595.
[35] Q. Zhi, Y. Gao, L. Lu, Z. Liu, P. Wang, Online Inspection of Weld Quality in Ultrasonic Welding of Carbon Fiber/Polyamide 66 without Energy Directors, Weld. J, 97(3) (2018) 65s-74s.
[36] A. Freddi, M. Salmon, Introduction to the Taguchi method, in:  Design principles and methodologies, Springer, (2019) 159-180.
[37] H. Atil, Y. Unver, A different approach of experimental design: Taguchi method, Pakistan journal of biological sciences, 3(9) (2000) 1538-1540.
[38] https://amajsonic.com.
[39] D. Broek, Elementary Engineering Fracture Mechanics, Springer Science & Business Media, 1986.
[40] Standard ASTM D7905/D7905M–14, Standard Test Method for Determination of the Mode II Interlaminar Fracture Toughness of Unidirectional Fiber-Reinforced Polymer Matrix Composites, in, 2014.
[41] W. Barrois, Use of Standardized Sequences of Flight-by-Flight Load Spectra in Fatigue Testing of Structural Aircraft Components, Engineering Fracture Mechanics, 9(2) (1977) 317-330.
[42] Z. Suo, G. Bao, B. Fan, Delamination R-Curve Phenomena Due to Damage, Journal of the Mechanics and Physics of Solids, 40(1) (1992) 1-16.
[43] K.N. Anyfantis, N.G. Tsouvalis, A 3D Ductile Constitutive Mixed-Mode Model of Cohesive Elements for the Finite Element Analysis of Adhesive Joints, Journal of Adhesion Science and Technology, 27(10) (2013) 1146-1178.
[44] K.N. Anyfantis, N.G. Tsouvalis, A Novel Traction–Separation Law for the Prediction of the Mixed Mode Response of Ductile Adhesive Joints, International Journal of Solids and Structures, 49(1) (2012) 213-226.
[45] M. De Moura, J. Gonçalves, J. Chousal, R. Campilho, Cohesive and Continuum Mixed-Mode Damage Models Applied to the Simulation of the Mechanical Behaviour of Bonded Joints, International Journal of Adhesion and Adhesives, 28(8) (2008) 419-426.
[46] K. Dadej, B. Surowska, Analysis of cohesive zone model parameters on response of glass-epoxy composite in mode II interlaminar fracture toughness test, composites theory and practice, 16(3) (2016) 180-188.
[47] M.R. Choudhury, K. Debnath, Analysis of tensile failure load of single-lap green composite specimen welded by high-frequency ultrasonic vibration, Materials Today: Proceedings, 28 (2020) 739-744.
[48] A.J. Russell, K.N. Street, Moisture and Temperature Effects on the Mixed-Mode Delamination Fracture of Unidirectional Graphite/Epoxy, in:  Delamination and Debonding of Materials, ASTM International, 1985.
[49] G.R. Irwin, J. Kies, Critical Energy Rate Analysis of Fracture Strength, Spie Milestone Series MS, 137 (1997) 136-141.
[50] Y. Wang, J. Williams, Corrections for Mode II Fracture Toughness Specimens of Composites Materials, Composites Science and Technology, 43(3) (1992) 251-256.
[51] M. De Moura, J. Oliveira, J. Morais, J. Xavier, Mixed-Mode I/II Wood Fracture Characterization Using the Mixed-Mode Bending Test, Engineering Fracture Mechanics, 77(1) (2010) 144-152.