Investigation on Joining Divergent Geometric Profiles using 20KHz Ultrasonic Sound Waves

In the modern scenario of solid-state welding, Ultrasonic metal welding (USMW) has emerged as one of the successful and efficient method of joining metal specimens with dissimilar profiles (cylindrical – flat). As the methods and procedures involved in repairing flaws are not cost effective, many industries require a systematic approach to forecast weld strength before manufacturing the weld joints. This study is carried out to develop a mathematical model for predicting the weld strength using response surface method. Experiments are conducted based on response surface design matrix comprising of five factors such as the weld time, amplitude, weld pressure, sheet thickness and wire diameter and the weld strength of each experimental trials evaluated in terms of T-peel load are measured. Also, a feed forward back propagation artificial neural network with supervised training has been developed to predict the T-peel load and it tends to be consistent throughout the entire range values.