Dynamic simulation method for ultrasonic welding process of multiple layers of thin plates

By using a dynamic simulation method for ultrasonic welding of multi-layer thin plates, combined with solid and shell element models, and optimizing the material failure threshold using experimental data, the problem of simulating the non-uniformity of mechanical properties of welded joints was solved. This method enables accurate simulation of welded joints under complex stress conditions and supports the optimization of safety performance of lightweight vehicle bodies in new energy vehicles.

CN121503039APending Publication Date: 2026-02-10YANGTZE UNIVERSITY
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Patent Information

Application Number
CN202511638190.4
Authority / Receiving Office
CN · China
Patent Type
Applications(China)
Current Assignee / Owner
Filing Date
2025-11-10
Publication Date
2026-02-10

AI Technical Summary

Technical Problem

Existing ultrasonic welding head simulation methods cannot accurately simulate the non-uniformity of mechanical properties during ultrasonic welding, especially in the welding of multi-layer thin plates, resulting in discrepancies between the simulation results and the actual results of the weld joint.

Method used

A dynamic simulation method for ultrasonic welding of multilayer thin plates was adopted. Through a multi-step closed-loop process, combined with solid element and shell element models, detailed and simplified models were established using LS-DYNA software. The models were calibrated and optimized using experimental data. Machine learning algorithms were used to dynamically correct the material failure threshold, and a multi-physics field coupled adaptive optimization module was established to realize the dynamic adjustment and mapping of parameters.

Benefits of technology

It improves the accuracy and stability of welded joint simulation, can realistically reproduce the mechanical behavior of welded joints under complex stress conditions, shortens the technology verification cycle, and ensures the connection reliability and safety performance of lightweight vehicle bodies for new energy vehicles.

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Abstract

The invention discloses a dynamic simulation method for the ultrasonic welding process of multiple layers of thin plates. According to the method, simulation model combinations of different dimensions are provided, so that the problem of simulation of the mechanical property non-uniformity of the welded joint is effectively solved. The entity unit detailed model can finely present the microstructure characteristics of the welding joint, including the interface reaction area and the welding seam fusion state of each layer of plate, and the shell unit simplified model greatly improves the calculation efficiency on the premise of ensuring the engineering precision; the part impact test simulation model further combines the material failure behavior with the actual working condition. The three models support one another through a unified material failure setting system, the performance difference between a welding seam area and base metal is captured, the dynamic response rule under the impact load is reflected, and the simulation result can truly reproduce the mechanical behavior of a welding joint in the complex stress state.
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