Vibration Welding Design Guidelines

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Discover the vibration welding process

Weld Joint Design

Standard Vibration

Hybrid Vibration

TWeld Rib Thickness> 1.5 mm> 1.5 mm
noneWeld Rib Height< 3 × T< 3 × T
FWeld Rib Radius (Fillet)> 1.5 mm> 1.5 mm
WWeld Surface WidthT + AmplitudeT + Amplitude
AWeld Angle< 10°, ideally 0°< 15°, ideally 0°
DWeld Depth0.8 − 1.0 mm0.8 − 1.0 mm
HReturn Flange Height> 2 mm> 2 mm
RReturn Flange Thickness> 1.5 mm> 1.5 mm
SWeld Support Width3 − 5 mm3 − 5 mm
CInternal Component ClearanceN/A> 0.5 mm
BFlash Retaining Rib Height1.5 mm1.5 mm

Amplitude: High-frequency (240 Hz) amplitude is typically 0.4 – 1.8 mm. Low-frequency (120 Hz) amplitude is typically 1.8 – 4.0 mm.

Vibration Welding Angles

It is important to have a good vibration axis. In order for one component to be able to vibrate against the other, one axis must be as flat as possible to allow for the motion. The maximum angle should be less than 10°. Hybrid vibration welding may allow for angles up to 15°, but the parts should still be kept as flat as possible in the direction of vibration welding.

The assembly may be angled in the axis opposite of the direction of vibration as shown below.

Weld Surface Contour

To illustrate this concept further, the blue line in the next image shows the contour of the weld surface in the taillamp example. The green surface illustrates the basic curvature of the taillamp’s weld surface. It is only possible to vibrate in the direction perpendicular to the curvature.

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