Energy Analysis during Ultrasonic Welding of PP: EDS-ABS Polymer Blends – Experimental Investigation, Statistical Assessment and Mathematical Modelling for Energy and Power Signal Dynamics

This research provides an intensive experimental investigation of the energy issues with respect to tensile strength and energy consumption during ultrasonic welding of thermoplastic PP and Electrostatic Discharge ABS polymers. A scheduled set of 27 experiments were performed through varying amplitude, weld pressure, and weld time that led to the identification of the effect of process parameters on joint quality and energy usage. Quantitative data were gathered and analysed to recognize patterns to improve efficiency. The Pearson correlation coefficient was applied to confirm relations between the input variables and the response variables. The analysis indicated a strong positive correlation of weld time with energy consumed, and with the tensile strength and amplitude of the weld. The findings can help create energy-efficient welding methods for polymer materials used in energy systems. Power signals and harmonics analysis is performed using MATLAB to understand its variation when the process is ON and it provides an insight into signals and control mechanism to be fine-tuned for ultrasonic welding process.