SJP ULTRASONICS PVT LTD

Presenting to – Varroc

Sub. – USW Feasibility

Product Name – EBOX HOUSING

Address :- Unit No. 1 & 2, Shivshankar Complex 2, Bldg. No. 5,Opp. Golden Chariot Hotel,
Highway Vasai (East), Dist. Palghar, Maharashtra – 401205 , Email: sjpultrasonics@gmail.com
 Cad data received :

Dimensions = 80 x 63 x 44 (in mm)

 Part detail :
(Housing)

(Cover)

Material details:
Cover - PC

Housing - PC
Mail Reference :
 Ultrasonic Welding of Parts :

• Welding area highlighted in red color.

71 mm

59 mm

Welding area is 71 x 59 (mm).

 Section view analysis :

Present joint design

A
A (Before welding condition)

Section A-A
Please make changes as per suggested in next slide.
*All Dimensions are in mm
 Section view analysis :

Modified joint design Flashes will be visible only internally.

A
A (Before welding condition)

Section A-A
Need to modify joint design as shown above.
*All Dimensions are in mm
Horn & Fixture direction :

Horn

Fixture
 Suggestion :

Highlighted area needs to be increased to at least 3 mm for

enough resting in fixture.
 Observations :

1. Present part material combination is [PC + PC] feasible for ultrasonic welding.
2. Need to modify the part joint design as shown in the report.
3. Material use to manufacture horn can be Aluminum / Titanium.
4. Fixture material is Aluminum (with pouring objective).
5. Complete operation will be done in one stroke.
6. 1 Fixture and 1 horn is required for complete part welding.
7. 15 KHz ultrasonic welding machine will be suitable for this application.
8. If the welding part is chrome plated then dust will form during ultrasonic welding.
9. Do not hard coat welding area.
10. Do not metalize welding area.
11. Shrinkage and warpage above limit not allowed.
12. Part to part variation is not allowed.
13. Polythene sheet is compulsory to use between horn & part to avoid marking on parts if
there aesthetic finishing requirement after ultrasonic welding.
 Thanks and Regards

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