Dukane iq series User Manual page 137

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Problem
There is a loose fit between the staked head and the part being attached.
Probable Cause
The holding force was removed before
the stud head could solidify.
Insufficient force is being applied to
the staked head during the hold time.
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Problem
The stud is collapsing at its base.
Probable Cause
There is a sharp corner near the base
of the stud.
The stud is not centered in the
horn cavity.
The base is melting before the
head forms.
Too much pressure is applied before
the ultrasound is activated.
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Problem
The base is melting before the head forms.
Probable Cause
The trigger force is too high.
The horn amplitude is insufficient.
The downstroke speed is too fast.
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Dukane Manual Part No. 403-586-02
Staking
Continued from Previous Page
Solution
If using a dual pressure system, use
Pressure 2 in the hold portion of the weld cycle
(Pressure 2 should be higher than
Pressure 1).
Increase the hold time/distance.
Increase the stud diameter.
Reduce the size of the staking cavity.
Lower the bottom stop for the horn's
travel.
Solution
Radius the stud at the base.
Center the stud under the horn cavity.
Use a knurled tip
See the problem section below entitled
"The base is melting before the head forms."
Use pre-triggering.
Solution
Reduce the trigger force.
Pre-trigger the ultrasound.
Increase the amplitude.
Use hydraulic speed control.
Use a slower downstroke speed.
Section 9 - Troubleshooting
Continued
Page 129