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Advanced Ultrasonic Joining & Battery Packaging

Ultrasonic Torsion Welding (UTW) Prepress Calculator

Calculate acoustic torsional oscillation amplitudes, interfacial shear stress distributions, dynamic torque, and knurl toolpath geometries for circular hermetic welds on cylindrical battery caps, sensor housings, and dissimilar metal tubes.

Process Parameters & Inputs

Circular weld seam outer diameter in mm (e.g., 21700 or 4680 battery cap).
Flange wall thickness being joined in mm.
Peak torsional linear scrub amplitude at outer periphery in micrometers (µm).
Axial clamping pneumatic/servo force in Newtons (N).
Ultrasonic activation time in seconds.

Calculated Engineering Metrics

Dynamic Acoustic Torque
54.2Nm
Interfacial Shear Stress
168MPa
Total Ultrasonic Energy
1180Joules
Circular Bond Area
101mm²

Toolpath & Geometry Simulation

Engineering Reference:
→ Read the Ultrasonic Torsion Welding Prepress Tooling & CAM Vector Guide

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Engineering Principles & Formula Reference

Ultrasonic Torsional Welding (UTW) oscillates radially around the central Z-axis rather than longitudinally. This applies uniform pure shear stress across 360° of circular weld seams without asymmetrical lateral vibration.

Torsional Torque & Total Energy:
T_{acoustic} = \frac{2}{3} \cdot \mu_{friction} \cdot F_{clamp} \cdot \frac{R_o^3 - R_i^3}{R_o^2 - R_i^2}
\tau_{shear} = \frac{T_{acoustic} \cdot R_o}{J_{polar}} = \frac{2 T_{acoustic} R_o}{\pi (R_o^4 - R_i^4)}
E_{weld} = 2\pi f_{US} \cdot T_{acoustic} \cdot \left(\frac{\theta_{amp}}{R_o}\right) \cdot t_{weld}

Essential for hermetic EV battery packaging, aluminum-to-copper cylindrical terminals, and airbag inflator initiator caps where linear scrub would fracture delicate internal glass seals.