GM Uses Abaqus to Predict Welding Energy, Distortion and Temperature Distribution

January 22, 2014

General Motors Company: Investigators at General Motors Report Findings in Industrial Engineering

Researchers detail new data in Industrial Engineering. According to news reporting from Warren, Michigan, by VerticalNews journalists, research stated, "Ultrasonic welding is a solid-state bond created using ultrasonic energy. It has been used in the semiconductor industry for several decades, and more recently, in the automotive industry such as for lithium-ion battery welding."

The news correspondents obtained a quote from the research from General Motors, "Although there existed numerical simulations for ultrasonic welding, the models were limited to two-layer and like materials stackups. In this study, finite element theories are introduced and simulation procedure is established for multiple sheets and dissimilar metal ultrasonic welding. The procedures require both ABAQUS/Standard and ABAQUS/Explicit to simulate the coupled mechanical-thermal phenomena over the entire weld duration with moderate computational cost. The procedure is verified and used to simulate selected specific cases involving multiple sheets and dissimilar materials, i.e., copper and aluminum. The simulation procedure demonstrates its capability to predict welding energy, distortion, and temperature distribution of the workpieces. Case studies of ultrasonic welding simulations for multiple layers of lithium-ion battery tabs are presented."

According to the news reporters, the research concluded: "The prediction leads to several innovative ultrasonic welding process designs for improved welding quality."

For more information on this research see: Ultrasonic Welding Simulations for Multiple Layers of Lithium-Ion Battery Tabs. Journal of Manufacturing Science and Engineering-Transactions of the ASME, 2013;135(6):88-100. Journal of Manufacturing Science and Engineering-Transactions of the ASME can be contacted at: Asme, Two Park Ave, New York, NY 10016-5990, USA.

Additional information may be obtained by contacting D. Lee, Gen Motors Co, Global R&D Center, Mfg Syst Res Lab, Warren, MI 48090, United States. Additional authors for this research include E. Kannatey-Asibu and W. Cai.

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