考虑变摩擦和声软化效应的超声焊接多场耦合模拟与分析

doi:10.3901/JME.2025.02.086

机械工程学报 ›› 2025, Vol. 61 ›› Issue (2): 86-96.doi: 10.3901/JME.2025.02.086

扫码分享

考虑变摩擦和声软化效应的超声焊接多场耦合模拟与分析

胡伟飞^1,2,3, 邓晓豫^1,3, 张桐舟^1,3, 刘振宇^1,2,3, 谭建荣^1,2,3

1. 浙江大学流体动力与机电系统国家重点实验室杭州 310027;
2. 设计工程及数字孪生浙江省工程研究中心杭州 310027;
3. 浙江大学机械工程学院杭州 310027

收稿日期:2024-02-21 修回日期:2024-08-15 出版日期:2025-01-20 发布日期:2025-02-26
作者简介:胡伟飞(通信作者)，男，1985年出生，研究员，博士研究生导师。主要研究方向为数字孪生、人工智能、不确定性优化设计。E-mail：weifeihu@zju.edu.cn;邓晓豫，男，1997年出生，硕士研究生。主要研究方向为数字化仿真。E-mail：dengxy2016@zju.edu.cn;张桐舟，男，1998年出生，博士研究生。主要研究方向为数字孪生、仿真模型一致性验证。E-mail：t.z.zhang@zju.edu.cn;刘振宇，男，1974年出生，教授，博士研究生导师。主要研究方向为复杂装备数字化设计。E-mail：liuzy@zju.edu.cn;谭建荣，男，1954年出生，教授，博士研究生导师，中国工程院院士。主要研究方向为机械设计及理论、计算机辅助设计与图形学、数字化设计与制造。E-mail：egi@zju.edu.cn
基金资助:
国家重点研发计划(2018YFB1201802)、浙江省自然科学基金重点(LZ22E050006)和流体动力与机电系统国家重点实验室自主课题(SKLoFP_ZZ_2102)资助项目。

Multiphysics Coupling Simulation and Analysis of Ultrasonic Welding Considering Variable Friction and Acoustic Softening Effects

HU Weifei^1,2,3, DENG Xiaoyu^1,3, ZHANG Tongzhou^1,3, LIU Zhenyu^1,2,3, TAN Jianrong^1,2,3

1. State Key Laboratory of Fluid Power and Mechatronic Systems, Zhejiang University, Hangzhou 310027;
2. Engineering Research Center for Design Engineering and Digital Twin of Zhejiang Province, Hangzhou 310027;
3. School of Mechanical Engineering, Zhejiang University, Hangzhou 310027

Received:2024-02-21 Revised:2024-08-15 Online:2025-01-20 Published:2025-02-26

摘要/Abstract

摘要： 超声焊接作为一种固相连接技术，广泛用于功率半导体的封装工艺中。针对试验观测方式难以研究超声焊接复杂瞬态过程及其连接机理的难题，建立了一个“声-热-力”多场耦合的三维有限元模型来研究这一复杂动态过程，考虑了热和摩擦的双向耦合作用，在热软化的基础上引入了超声对材料的软化效应，并使用模拟得到的工件振幅来动态更新声软化系数，提高了有限元模型的准确性。基于该耦合模型，进一步探究了金属超声焊接过程中工件振幅传递、温度场分布以及塑性变形等复杂机械行为，并分析了振幅、压力等工艺参数对焊接过程的影响。结果表明，工件温度和塑性变形的模拟结果与实测数据吻合较好；超声振动能量在工件间传递存在衰减；工件焊接区域中心温度明显高于焊接边缘温度，但仍远低于材料熔化温度；热和声软化对工件塑性变形均有显著作用，其中声软化的贡献率约为38%。此外，超声焊接工艺参数对焊接过程有较大影响，对改善焊接质量具有潜在意义。

关键词: 超声焊接, 多物理场耦合, 振幅传递, 温度场分布, 塑性变形

Abstract: As a solid-state bonding technology, ultrasonic welding is often used in the packaging process of power semiconductors. It is difficult to investigate the complex transient process and bonding mechanism of ultrasonic welding only by experimental observation. To explore this complex dynamic process, A three-dimensional finite element model of “acoustic-thermal-mechanical” multi-physics coupling is established. The bidirectional coupling of heat and friction is considered, and the softening effect of ultrasonic on the material is introduced on the basis of thermal softening. The acoustic softening coefficient is dynamically updated by the amplitudes of the two workpieces obtained from the simulation outputs, which improves the accuracy of the finite element simulation model. Based on the simulation model, the complex mechanical behavior of the workpieces is further investigated, including amplitude transfer, temperature distribution and plastic deformation. The influence of process parameters, namely amplitude and pressure, on the welding process is also analyzed. The result shows that the simulated results of temperature and plastic deformation of the workpieces are consistent with the experimental data. The ultrasonic vibration energy decays when the vibration is transferring between the workpieces. The temperature at the center of the welding area is significantly higher than that at the edge, but is still far lower than the melting point of the material. Both thermal and acoustic softening have significant effects on the plastic deformation of the workpieces, and the contribution ratio of acoustic softening to the deformation is about 38%. In addition, ultrasonic welding process parameters have great influence on the welding process, which has potential meaning for improving welding quality.

Key words: ultrasonic welding, multi-physics coupling, amplitude transfer, temperature distribution, plastic deformation

中图分类号:

TG453

胡伟飞, 邓晓豫, 张桐舟, 刘振宇, 谭建荣. 考虑变摩擦和声软化效应的超声焊接多场耦合模拟与分析[J]. 机械工程学报, 2025, 61(2): 86-96.

HU Weifei, DENG Xiaoyu, ZHANG Tongzhou, LIU Zhenyu, TAN Jianrong. Multiphysics Coupling Simulation and Analysis of Ultrasonic Welding Considering Variable Friction and Acoustic Softening Effects[J]. Journal of Mechanical Engineering, 2025, 61(2): 86-96.

导出引用管理器 EndNote|Reference Manager|ProCite|BibTeX|RefWorks

链接本文: http://www.cjmenet.com.cn/CN/10.3901/JME.2025.02.086

http://www.cjmenet.com.cn/CN/Y2025/V61/I2/86

参考文献

[1] 张文武，潘浩，马秋晨，等. 功率超声微纳电子封装互连技术研究进展[J]. 机械工程学报，2022，58(2)：100-121. ZHANG Wenwu，PAN Hao，MA Qiuchen，et al. Review of power ultrasonic micro-nano joining technology for electronic manufacturing[J]. Journal of Mechanical Engineering，2022，58(2)：100-121.
[2] MATHENY M，GRAFF K. Ultrasonic welding of metals[M]//Power ultrasonics. Amsterdam：Elsevier. 2015：259-293.
[3] SANGA B，WATTAL R，NAGESH D. Mechanism of joint formation and characteristics of interface in ultrasonic welding：Literature review[J]. Periodicals of Engineering and Natural Sciences (PEN)，2018，6(1)：107-119.
[4] NI Z，YE F. Ultrasonic spot welding of aluminum alloys：A review[J]. Journal of Manufacturing Processes，2018，35：580-594.
[5] YADAV S，DOUMANIDIS C. Thermomechanical analysis of an ultrasonic rapid manufacturing (URM) system[J]. Journal of Manufacturing Processes，2005，7(2)：153-161.
[6] 马遵农，张延松，赵亦希. 多层箔片超声焊接的摩擦能量耗散机理及影响因素研究[J]. 上海交通大学学报，2022，56(6)：772-783. MA Zunnong，ZHANG Yansong，ZHAO Yixi. Mechanism and influencing factors of frictional energy dissipation in multilayer ultrasonic welding[J]. Journal of Shanghai Jiao Tong University，2022，56(6)：772-783.
[7] AMBEKAR T. Additional studies on interface temperatures and bonding mechanisms of ultrasonic welds[J]. Weld. J.，1970，49(5)：196-200.
[8] HO J，CHEN C，WANG C. Thin film thermal sensor for real time measurement of contact temperature during ultrasonic wire bonding process[J]. Sensors and Actuators A：Physical，2004，111(2-3)：188-195.
[9] CHEN Y，BAKAVOS D，GHOLINIA A，et al. HAZ development and accelerated post-weld natural ageing in ultrasonic spot welding aluminium 6111-T4 automotive sheet[J]. Acta Materialia，2012，60(6-7)：2816-2828.
[10] ZHAO Y，LI D，ZHANG Y. Effect of welding energy on interface zone of Al-Cu ultrasonic welded joint[J]. Science and Technology of Welding and Joining，2013，18(4)：354-360.
[11] SASAKI T，WATANABE T，HOSOKAWA Y，et al. Analysis for relative motion in ultrasonic welding of aluminium sheet[J]. Science and Technology of Welding and Joining，2013，18(1)：19-24.
[12] KOMIYAMA K，SASAKI T，WATANABE Y. Effect of tool edge geometry in ultrasonic welding[J]. Journal of Materials Processing Technology，2016，229：714-721.
[13] LI H，CAO B，YANG J，et al. Modeling of resistance heat assisted ultrasonic welding of Cu-Al joint[J]. Journal of Materials Processing Technology，2018，256：121-130.
[14] PALARDY G，SHI H，LEVY A，et al. A study on amplitude transmission in ultrasonic welding of thermoplastic composites[J]. Composites Part A：Applied Science and Manufacturing，2018，113：339-349.
[15] ZHANG C，LI L. A coupled thermal-mechanical analysis of ultrasonic bonding mechanism[J]. Metallurgical and Materials Transactions B，2009，40(2)：196-207.
[16] VRIES E. Mechanics and mechanisms of ultrasonic metal welding[D]. Columbus：The Ohio State University，2004.
[17] 王帅，敖三三，何思贤，等. NiTi形状记忆合金超声波焊接温度场数值计算与分析[J]. 机械工程学报，2021，56(24)：88-95. Wang Shuai，AO Sansan，HE Sixian，et al. Numerical calculation and analysis of temperature distribution during ultrasonic welding process for NiTi shape memory alloy[J]. Journal of Mechanical Engineering，2021，56(24)：88-95.
[18] KIM W，ARGENTO A，GRIMA A，et al. Thermo- mechanical analysis of frictional heating in ultrasonic spot welding of aluminium plates[J]. Proceedings of the Institution of Mechanical Engineers，Part B：Journal of Engineering Manufacture，2011，225(7)：1093-1103.
[19] CHEN K，ZHANG Y. Numerical analysis of temperature distribution during ultrasonic welding process for dissimilar automotive alloys[J]. Science and Technology of Welding and Joining，2015，20(6)：522-531.
[20] CHEN K，ZHANG Y，WANG H. Effect of acoustic softening on the thermal-mechanical process of ultrasonic welding[J]. Ultrasonics，2017，75：9-21.
[21] LI H，CAO B，LIU J，et al. Modeling of high-power ultrasonic welding of Cu/Al joint[J]. The International Journal of Advanced Manufacturing Technology，2018，97(1-4)：833-844.
[22] DU P，CHEN W，DENG J，et al. Effects of knurl tooth angle on mechanical and thermal behaviors of aluminum ultrasonic welding[J]. Ultrasonics，2020，108：106207.
[23] ZHANG X，XIAO B，MA Z. A transient thermal model for friction stir weld. Part I：The model[J]. Metallurgical and Materials Transactions A，2011，42(10)：3218-3228.
[24] SIDDIQ A，EL SAYED T. Acoustic softening in metals during ultrasonic assisted deformation via CP-FEM[J]. Materials Letters，2011，65(2)：356-359.
[25] SOUNDARARAJAN V，ZEKOVIC S，KOVACEVIC R. Thermo-mechanical model with adaptive boundary conditions for friction stir welding of Al 6061[J]. International Journal of Machine Tools and Manufacture，2005，45(14)：1577-1587.
[26] GAO Y，DOUMANIDIS C. Mechanical analysis of ultrasonic bonding for rapid prototyping[J]. J. Manuf. Sci. Eng.，2002，124(2)：426-434.
[27] ZHAN X，BU H，GAO Q，et al. Temperature field simulation and grain morphology on laser welding- brazing between Ti-6Al-4V and 1050 aluminum alloy[J]. Materials Research Express，2019，6(5)：056551.
[28] 李欢. 基于数值模拟的超声焊及电阻热辅助超声焊过程研究[D]. 广州：华南理工大学，2018. LI Huan. Study of the ultrasonic welding and resistance heat assisted welding process based on simulation analysis[D]. Guangzhou：South China University of Technology，2018.

考虑变摩擦和声软化效应的超声焊接多场耦合模拟与分析

Multiphysics Coupling Simulation and Analysis of Ultrasonic Welding Considering Variable Friction and Acoustic Softening Effects

PDF

可视化

摘要/Abstract

引用本文

使用本文

参考文献

相关文章 15

编辑推荐

Metrics

本文评价

[1]	杨泽坤, 李韶华, 杨绍普. 从低阶建模到全域智能：分布式驱动车辆多物理场耦合机理、估计与控制综述[J]. 机械工程学报, 2026, 62(8): 221-245.
[2]	王岚, 樊宇航, 程晖. 复合材料沉头衬套螺栓干涉连接渐进损伤数值模拟分析方法[J]. 机械工程学报, 2025, 61(7): 156-166.
[3]	赵文勇, 魏艳红, 胥国祥, 胡庆贤, 王耀伟. 基于一体化模型的铝合金MIG增材单道形貌、传热及流动行为研究[J]. 机械工程学报, 2025, 61(22): 97-108.
[4]	陈扬建, 易军, 王宗伟, 陈冰, 邓辉. 电解质等离子体抛光的多物理场耦合仿真及实验研究[J]. 机械工程学报, 2025, 61(1): 360-370.
[5]	韩建超, 张孟非, 王斌, 国生辉, 贾燚, 王涛. 钛合金电致塑性本构方程及多物理场耦合分析[J]. 机械工程学报, 2024, 60(9): 421-433.
[6]	蒋飞, 赵升吨, 范淑琴, 王可心, 陈超. 剥肋滚压复合工艺及其设备研究[J]. 机械工程学报, 2024, 60(8): 132-142.
[7]	崔学习, 万敏, 吴向东, 关铂镔, 周兵营. 基于应变演化的集中性失稳确定方法[J]. 机械工程学报, 2023, 59(22): 234-244.
[8]	李涛, 黄惟琦, 龙归, 杨思铄, 张建国, 肖峻峰, 许剑锋. 单晶硅的激光抛光表面形貌演化[J]. 机械工程学报, 2023, 59(21): 52-64.
[9]	王权岱, 强昊文, 叶思彤, 李鹏阳, 郑建明, 李言. 光-热双固复合材料3D打印成型数值模拟及实验验证[J]. 机械工程学报, 2023, 59(15): 293-303.
[10]	宋明, 马帅, 杜传胜, 蒋文春, 王炳英. 不同流道布置的平板式固体氧化物燃料电池蠕变损伤研究[J]. 机械工程学报, 2023, 59(10): 76-84.
[11]	闫英, 孙国荣, 董晋彤, 周平. 抽吸电极电解加工微小孔加工工艺研究[J]. 机械工程学报, 2022, 58(5): 268-277.
[12]	蔡旺, 王春晖, 孙朝阳, 马晋遥, 李月敏, 姜军, 张跃飞. 耦合温度效应晶体塑性的TWIP钢变形行为研究[J]. 机械工程学报, 2022, 58(20): 283-293.
[13]	韩建超, 姚昊明, 贾燚, 谢广明, 王涛. 新型三相TiAl合金高温塑性变形行为及流动软化研究[J]. 机械工程学报, 2022, 58(16): 77-88.
[14]	王青, 李怡, 林焱, 徐秋元, 连雯. 电力变压器铁心振动特性分析^*[J]. 电气工程学报, 2022, 17(1): 114-121.
[15]	安琪, 索双富, 林福严, 白玉柱, 耿海旭, 时剑文. 平面磨削粗糙表面的微观接触模型[J]. 机械工程学报, 2020, 56(7): 240-248.