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Ultrasonic complex vibration welding systems with complex vibration converter using two-dimensional vibration stress were proved significantly superior welding method compared with conventional welding with linear vibration. Ultrasonic complex vibration welding systems are significantly effective for welding of same and different metal parts and many lapped foils such as aluminum and copper electrode foils and terminals which are essential for electronic devices, Li-ion battery or EDLC electrodes and other various industry fields. 19.5 kHz complex vibration systems using various complex vibration welding tips which are exchangeable by a connecting bolt have been proved very useful for various welding specimens. But, more higher frequency system is desired to improve welding characteristics for smaller and special welding specimens. To decrease required vibration amplitude and decrease vibration damage of welding specimen, 27 kHz and 40 kHz complex vibration welding systems using various exchangeable welding tips were designed newly. Required vibration amplitudes for 27 kHz and 40 kHz welding system are 62% and 34% compared with 19.5 kHz ultrasonic welding system by the research results on frequency characteristics of ultrasonic welding. The complex vibration systems uses complex vibration converter with diagonal slit and driven by a longitudinal vibration driving system in one-dimensional configuration. 27 kHz and 40 kHz complex vibration welding systems using various welding tips were developed using complex vibration converter with diagonal slits. The complex vibration converter is designed using equivalent electric transmission line method using measured acoustic impedance slit part, and FEM. To secure sufficient working space, complex vibration converter was designed as one-wave longitudinal length mode. The 27 kHz complex vibration converter with slit part is 38 mm in diameter and vibrates in one longitudinal wavelength mode. The converter has four 12-mm-square welding tip installing positions at the free edge which vibrates in circular to elliptical locus. Longitudinal vibration distribution is 5/4 wavelength and torsional vibration distribution is 7/4 wavelength along the vibration system between the free edge of the converter and the nodal part of longitudinal driving system. Elliptical to circular vibration locus is obtained in the case where vibration difference between longitudinal and torsional vibration at the free end of the converter is near to 90 degrees. Various non-resonant and resonant complex transverse vibration welding tip installed in the free edge by a connecting bolt were driven in elliptical to elliptical vibration locus and various welding specimen were welded successfully. Various complex vibration welding tips for various welding specimens can be installed by a connecting bolt. Various 12-mm-diameter complex vibration welding tips are installed at the free edge of the 27 kHz complex vibration converter with a connecting bolt. Various complex vibration welding tip including long and thin several tarnsverse complex vibration length hard metal welding tip for cylindrical Li-ion battery could be changed easily by a connecting bolt. The complex vibration converter is designed using equivalent electric transmission line method using measured acoustic impedance slit part. The 27 kHz system are driven using 1 kW amplifiers and elliptical to circular vibration loci are obtained at the welding tip. Required vibration velocity and static clamping force are small compared with conventional ultrasonic welding. Welding characteristics of various same and different metal specimens were studied. Using various resonant and non-resonant type complex vibration welding tips, welding specimens such as many lapped aluminum, copper, stainless steel foils and copper, nickel coated copper terminal specimens and various electronic devices were welded successfully with material strength and small deformation and without vibration fatigue damages. Furthermore, 40 kHz complex vibration welding system is under testing.  J. Tsujino and E. Sugimoto: Ultrasonic welding using a long and thin complex transverse vibration welding tip with vibration detector and static pressure controller, Proc. 2016 IEEE Ultrasonics Symposium, (2015), IEEE Xplore  J. Tsujino and E. Sugimoto: Ultrasonic Complex Vibration Welding of Many Metal Foils and Terminals of Li-ion Battery and Capacitor, Proc. 2016 IEEE Ultrasonics Symposium, (2016), IEEE Xplore.  J. Tsujino: Ultrasonic welding using complex vibration and high frequency vibration - Various ultrasonic vibration sources and frequency characteristics of ultrasonic welding -, Proc. 2011 IEEE International Ultrasonics Symposium, (2011) pp.1910-1919.
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