Döner Sürtünmeli Kaynak İşleminde Polipropilen Parçaların Birleşim Analizi ve Birleştirme Profilinin Geliştirilmesi

Plastik parçaların sökülemeyen birleştirmelerinde sürtünme kaynak, sürtünme-karıştırma kaynak, ultrasonik kaynak, kimyasal birleştirme, sıcak plaka kaynak gibi yöntemler kullanılmaktadır. Su arıtma cihazlarının filtre parçaların birleştirilmesinde çoğunlukla sürtünme kaynak yöntemlerinden döner sürtünme kaynağı kullanılmaktadır. Filtre parçalarının döner sürtünme kaynak sonrası iç kısımlarda yarı ergimiş yığılmalar oluşmaktadır. Bazı hassas filtrelerde iç kısımda oluşan yarı ergimiş yığılmalarda kopmalar sonucunda filtrelerin tıkanmasına sebep olmaktadır. Bu çalışmada filtre parçalarının iç kısımda oluşan yarı ergimiş yığılmayı hapsetmek için kaynak ağız tasarımının geliştirilmesi amaçlanmaktadır. Bu amaçla mevcut filtre parçalarının yarı ergimiş yığılma durumu ABAQUS programında (Lagrangian ve CEL (Coupled Eulerian Labrangian) yöntem) analiz/simülasyonlar yaparak yarı ergimiş yığılma durumu, termal analiz, stress, enerji verileri değerlendirilmiştir. Yarı ergimiş yığılma hapsedecek kaynak yapı tasarımı geliştirilerek, analizler tekrarlanmıştır. Elde edilen analizlerde; maksimum sıcaklığın 166,2 °C, kaynak sonrası ürün boyunda 1,98 mm kısalma olduğu ve 150 °C sıcaklığa 13,1 salisede ulaştığı bulunmuştur. Önerilen farklı kaynak ağızları çalışmalarından, N3 kaynak ağızının yarı ergiyik durumdaki hammaddeyi hapsetmesini daha iyi başarım sergilediği tespit edilmiştir.

Anahtar Kelimeler:

Döner sürtünme kaynak, ABAQUS, CEL Analiz, yarı ergimiş yıgılma analizi, kaynak ağız profil tasarımı

Joining Analysis of Polypropylene Parts in Rotary Friction Welding Process and Developing of Joints Profile

Various welding methods are used to produce non-detachable joints of plastic parts. These are friction welding (FW), friction-stir welding (FSW), ultrasonic welding, chemical bonding, and hot plate welding. Rotary friction welding (RFW) method, which is one of the FW methods, is generally used in joining the filter parts of water treatment devices. After RFW processes, semi-melted plastic accumulations tend to occur on the interior surfaces of the filter parts. In some cases, particles broken off from these accumulations can often clog sensitive filters. In this study, it is aimed to develop a welding joint profile design that can be used to confine the semi-melted agglomeration formed in the interior surfaces of the filter parts. For this purpose, the semi-melted agglomeration in the filter parts is analyzed/simulated utilizing the ABAQUS program by using Lagrangian and CEL (Coupled Eulerian-Lagrangian) methods, and their thermal analysis, stress, and energy data are evaluated. The analysis is repeated until the optimal welding structure design to confine the semi-melted agglomeration is developed. As a result of the analyses, it was determined that the maximum temperature reached is 166.2 °C, there was a 1.98 mm shortening in the length of the product after welding, and the temperature of 150 °C was reached in 13.1 milliseconds. From the several joint profile designs proposed, it was determined that the N3 joint profile design accommodates the semi-melt raw material better than the others.

Keywords:

Rotary Friction Welding, ABAQUS, CEL analysis, semi-melted agglomeration analysis, joint profile design,

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