Ultrasonic riveting and forming
The ultrasonic riveting makes possible an interlocking bonding of two thermoplastics or of thermoplastics with dissimilar materials, e. g. thermoset materials or metals.
In this process the sonotrode serves as a re-forming tool. It determines the forming of the riveting pin.
During the holding time (cooling phase) the sonotrode serves also as fixation stamp, thus the melted material cools down under pressure.
Advantages of ultrasonic riveting:
Disadvantages of ultrasonic riveting:
An optimal riveting joint should be based on the following preconditions:
In the following there are listed some established sonotrode materials:
Moreover, for an optimum riveting joint not only the sonotrode form and the material to be riveted are important, but also the process parameters like:
Sonotrode forms in titanium, aluminium and steel in the frequencies of 20, 30, and 40 kHz
Basic sonotrodes with several screw-in sonotrodes in a special machine
Basic machine with frame, generators, control cabinet and control
Exchangeable tooling with cylinders, converters, sonotrodes and fixture in a tool transfer trolley
Special machine for riveting a bezel with third brake light - 56 riveting spots
Complete machine with frame, generators, control cabinet, welding tool and control
Detailed view of the sonotrodes, holding-down clamp, cooling and contour fixture
Various riveting applications:
plastic clip of cell housing - 2 riveting spots
The design of the sonotrode operating surface and the riveting pin determine the form of the riveting head. Please see below some examples for an optimal design of the riveting head:
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