Optimization of technological parameters in ultrasonic welding of the polypropylene fabric using Taguchi and FCCCD methods

Ultrasonic welding is a welding method that has been applied for welding nonwoven fabrics, with many advantages such as fast speed, high reliability, easy automation and especially less pollution to the environment. This paper studies the optimization of technological parameters in the welding process such as welding time, pressure, and weld shape on the breaking strength of ultrasonic welding of Polypropylene (PP) nonwovens. To evaluate the influence level and find the reasonable technological parameters domain in the paper, the Taguchi method is used in combination with the face-centered central composite design (FCCCD) response surface method. The research results have determined the regression equations used to calculate the breaking strength for each weld shape as well as the optimal domain for the main technological parameters, ensuring the breaking strength of the weld. There are different degrees of influence of technological parameters (shape of the weld zone, welding time and welding pressure) on the breaking strength of ultrasonic welds. Among them, the influence level of welding time t is 45.31 %, the weld shape is Pattern 2 with the rate of 30.03 %, and the welding pressure is 24.66 %. Carrying out a verification test with the welding parameters: t=1.6 s, p=3.1 kgf/cm2, two patterns ( Pattern 2 and Pattern 3), the result of breaking strength for patterns was achieved. Pattern 2 has a difference of 1.19 % between the regression equation results and the actual experimental results, while the figure for Pattern 3 is 0.77 %. From these results, it is possible to select the appropriate technological parameters for ultrasonic welding equipment when processing products from nonwoven fabrics to ensure the highest quality and productivity