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Joining Analysis of Polypropylene Parts in Rotary Friction Welding Process and Developing of Joints Profile

Various welding methods are used to produce non-detachable joints of plastic parts. These are friction welding (FW), frictionstir welding (FSW), ultrasonic welding, chemical bonding, and hot plate welding. Rotary friction welding (RFW) method, which is one of the FW methods, is generally used in joining the filter parts of water treatment devices. After RFW processes, semi-melted plastic accumulations tend to occur on the interior surfaces of the filter parts. In some cases, particles broken off from these accumulations can often clog sensitive filters. In this study, it is aimed to develop a welding joint profile design that can be used to confine the semi-melted agglomeration formed in the interior surfaces of the filter parts. For this purpose, the semi-melted agglomeration in the filter parts is analyzed/simulated utilizing the ABAQUS program by using Lagrangian and CEL (Coupled Eulerian-Lagrangian) methods, and their thermal analysis, stress, and energy data are evaluated. The analysis is repeated until the optimal welding structure design to confine the semi-melted agglomeration is developed. As a result of the analyses, it was determined that the maximum temperature reached is 166.2 °C, there was a 1.98 mm shortening in the length of the product after welding, and the temperature of 150 °C was reached in 13.1 milliseconds. From the several joint profile designs proposed, it was determined that the N3 joint profile design accommodates the semi-melt raw material better than the others.