Automation, intellectual, and complexity are in the main stream of modern machinery development theme along with the light-weight and high-quality designs. This constant upgrading trend makes the application of aluminum alloy and plastic material in high demand. A wide variety of applications including many types of transportation vehicles and wind turbines need such aluminum alloy and plastic joining techniques. However, cyclic vibration during the operation may bring a big challenge to such dissimilar joining functions. Moreover, the rice husk generated from rice production process is always an environmental burden. The rice husk ash (RHA) which contains rich silica after burning is an excellent source to break the dissimilar bonding limitation. The pure organic silica exacted from RHA could be used as an interface coupling with plastic powder to the welding process. It could greatly improve the joining structure and enhance the joining strength. The transformation of agricultural waste to useful industrial material is a good practice to reinforce a sustainable environment, and makes this research valuable. This study used CNC micro drilling array for the aluminum alloy surface-roughening treatment, followed by adding the ABS and RHA mix powders and ultrasonic welding process to the dissimilar joining specimen. The tensile test was applied to analyze the welding function and define the strength as well. Additionally, the cantilever beam vibration system was used to study the vibration behavior during the actual operation. The finite element software can effectively evaluate the natural frequency and mode of vibration from the ABS and aluminum alloy welding compartments. This simulation can support the understanding and prediction of breaking behavior on the specimen under different vibration conditions. The laser doppler vibrometer (LDV) has also been used to measure the mode of vibration on the specimens. The acceleration-vibration curve was calculated from energy and vibration force of the specimen on the electromagnetic control vibration platform at resonant state. The experimental results show that the vibration life of dissimilar joint has been upgraded 26% for adding mix powder which contained 5 wt% rice husk ash in the interface for the same experimental parameter in 1.5 mm hole depth and a welding time of 2.5 seconds. In the same condition, the tensile shear load increased from 2.71 kN to 3.59. kN, which has an increment of 32% in tensile strength. It can help us to define the formulation of ABS and RHA, and more importantly, to improve the operation performance by lowering the vibration destruction force on the aluminum and plastic joining parts.
|Effective start/end date||2018/08/01 → 2019/10/31|
- 5052 aluminum
- ABS polymer
- vibration life time
- dissimilar joint
- ultrasonic welding
- rice husk ash
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