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Name of NGM Educator:

Richard Weber, Ph.D., Automated Manufacturing Professor
Naugatuck Valley Community College

Name of Host Company:

Branson Ultrasonics

Grade Level:

1st year students entering Engineering Technology

Student Work Types:

Type 1: Workshop Assignments and Exercise
Type 2: Manufacturing Lab Experiments
Type 3: Written Lab Reports
Type 4: (optional) Presentations

Task "A" Abstract:

The students are given a 3-hour workshop covering the theory, applications and equipment used to join plastic components by ultrasonic welding. During the workshop, the students complete several practical assignments at the end of each of the four workshop modules. The four modules are:

• Theory of ultrasonic welding
• Plastics (Polymers) and their properties
• Joint design for ultrasonically welding plastics
• Ultrasonic welding equipment and setup conditions
  

Task "A" Objectives:

1. To understand the fundamental theory of ultrasonic welding.
2. To select the correct plastic material and properties for the joint assembly.
3. To design a simple joint for ultrasonic welding.
4. To select the setup tools and operating conditions for an ultrasonic welder.

Task "A" Description and essential outcomes:

Objective 1 - Task "A"

• The student is able to explain how the ultrasonic welder generates the energy needed to melt the plastic at the joint interface.

• The student can diagram a typical ultrasonic welding system consisting of the power supply, converter, booster, and horn.

Objective 2 - Task "A"

• The student can explain the difference beween amorphous and semi-crystalline plastic.
• The student is able to define Tg, Tm, and Modulus of Elasticity related to the physical and mechanical properties fo plastics (polymers).

Objective 3 - Task "A"

• Given two plastic parts to assemble, the student is able to design a simple joint for ultrasonic welding.

Objective 4 - Task "A"

• The student is able to select the equipment setup tools needed to ultrasonically weld a specific joint for assembly of two plastic parts.
• The student can write a manufacturing process plan (MPP) with equipment operating parameters for a specified plastic joint assembly.

Abstract for Task "B"

The students conduct laboratory experiments to demonstrate and reinforce their learning knowledge of ultrasonic welding of plastic components. The lab assignments consist of specifying equipment operating conditions, selecting appropriate tooling, and actually running the equipment. The students collect data, analyze results, and prepare conclusions as part of a written report. The experiments include actual assemblies, such as welding a clear plastic window into a 'pager' (telecommunication) housing.

Objectives for Task "B"

1. To prepare procedures for operating an ultrasonic welder for plastics.
2. To select the appropriate tooling for ultrasonic welding equipment.
3. To correctly and safely operate the actual ultrasonic welding equipment.
4. To write a laboratory report presenting the data, analysis, and conclusions for the experiments.

Description and essential outcomes for Task "B"

Objective 1 - Task B

• The student can prepare a written procedure to operate the equipment for ultrasonic welding a clear plastic window into a "pager" housing.

Objective 2 - Task B

• The student can select the ultrasonic converter, booster, and horn for a specific plastic assembly and install them on the equipment.

Objective 3 - Task B

• The student can specify the equipment operating conditions and parameters for producing a plastic assembly.

Objective 4 - Task B

• The student completes a written lab report showing the data, analysis, and conclusions for producing an ultrasonically welded plastic assembly.

Resources Required:

For Task A - The workshop materials are prepared in hard copy for handouts to the students and on a CD for Powerpoint presentations.

For Task B - The equipment, tooling, and plastic components required for all the experiments have been supplied by the sponsoring company.

Prerequisites required:

A basic level of algebra and a high school diploma

Work Environment:

Lab setting

Educator's Comments:

The externship program is an excellent vehicle for getting hands-on experience in high technology areas.