In an ultrasonic welding operation of plastic parts, a system of internal electrical conductor strips were fatigue failing due to natural resonance excitation. A detailed parametrically based model was created to optimism the dynamic response thus tuning the connectors. The model included a melt front model due to frictional heating at the connector-plastic interface. Correlation to physical test data was completed and fracture behavior identified resulting in redesign and improvement of the device.
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