Wear mechanism on components under industrial load collectives

Abstract

In recent years, the loads on the tools for ultrasonic metal welding have increased due to the ever‐larger conductor cross‐sections and the increased complexity of the workpieces. The ever‐shorter cycle times boost this effect. As a result, the requirements on the service life of the tools, for example that of the anvil, are also increasing. Since the industrial load collective on a tool during the ultrasonic metal welding process is very complex, optimisation of tools requires detailed failure analyses as a reliable starting point. For this reason, present research deals with such a systematic failure analysis of the anvil. Hence, the wear mechanism could be clearly clarified, namely it is abrasion. Further, the subordinate mechanism of the abrasive wear is micro‐ploughing. The described research project was carried out in cooperation with the company Telsonic AG. Ultrasonic metal welding is an important business, as it is increasingly used in the production of connections in cable harnesses and highvoltage batteries for electric vehicles