Application and research of ultrasonic horn in ultrasonic. Tuning is the process of gradually removing material from the sonotrode until its measured resonant frequency is within tolerance on the target frequency a tolerance of 1% or less is common. Dependence of fundamental modal properties natural. Ultrasonic horns are axisymmetric devices that provide, with high efficiency, acoustic energy developed by a transducer that is working based on. This paper performs the analysis and design of acoustic horns for ultrasonic welding of plastic material, utilizing ansys finite element software. Design of ultrasonic transducers by means of the apparent elasticity method 297 where. Ultrasonic welding of thermoplastic materials is by far the most common form of ultrasonic assembly, and is used extensively in all major industries including. The connection is done at temperatures lower than melting, thus eliminating the heat affected zones. The singledriven ultrasonic elliptical vibration cutting sduevc system, which contains a unidirectional vibration transducer, a tailored horn, and one ultrasonic power, is simpler than the mode coupling uevc system. In addition, the sduevc device has a simpler control circuit than the mode coupling uevc device. Because composite ultrasonic horn designs can often eliminate the need to invest in additional assembly systems, they reduce equipment costs and minimize production time for customers. My webpage on this proved to be reasonably popular, and i. Pdf ultrasonic horn design for ultrasonic machining.
In addition, the horn maintains the pressure necessary to form a weld once joint surfaces have been melted. The model is based on websters wave propagation equation and as an objective function the minimization of the volume in structural equilibrium conditions was considered. The design of the ultrasonic horn cannot be separated from the numerical calculation method. The design of ultrasonic resonators with wide output cross sections. An ultrasonic horn also known as acoustic horn, sonotrode, acoustic waveguide, ultrasonic probe is a tapering metal bar commonly used for augmenting the oscillation displacement amplitude provided by an ultrasonic transducer operating at the low end of the ultrasonic frequency spectrum commonly between 15 and 100 khz. Sonotrode design and manufacturing instructions zvei. Intelligent assembly solutions guide to ultrasonic plastics. In this case, the vibratory apparatus, in addition to the ultrasonic horn further comprises. The ultrasonic horns design it is described in many technical books and papers. In order to maximise vibration amplitude uniformity. Ultrasonic plastic joining technical information pw3 part design for ultrasonic welding ultrasonic energy has been used to join thermo plastics for over 35 years. Pdf design and analysis of ultrasonic welding horn using finite. Pdf finite element analysis assisted design of ultrasonic horn for. Reliable performance of such horns is normally decided by the uniformity of amplitude of vibration at the working surface and the stresses developed.
The displacement amplification and stress distribution. The research is extended to study the possibility of design an ultrasonic transducer which can operate in multiple vibration modes by modify its geometric features. Thus, the available power the product of the power density and the piezoceramic volume varies inversely with the square of the frequency. In this paper, we focus on the optimization of the ultrasonic horn. Intelligent assembly solutions guide to ultrasonic. Ultrasonic horns and boosters selection guide engineering360. As geometry, the uh have a continuous crosssection variation along the longitudinal axis from a large diameter to a small diameter figure 1. For application requirements demanding a fullrange ultrasonic splicing system, branson offers the ultrasplice system, capable of splicing from 0. Finite element analysis assisted design of ultrasonic horn for plastic welding. The main design principles can be found in 5 6, 7, 9. Horn design for ultrasonic vibrationaided equal channel angular pressing r. Reliable performance of such horns is normally associated with the amplitude of vibration, uniformity of vibration amplitude at the working surface and the avoidance of modal participation by nontuned modes at the operating frequency. The device is necessary because the amplitudes provided by the. The technical notes are organized in the following sections.
The wave front of ultrasonic radiation changes in accordance with the sectional area which can be expressed ass sx. This paper performs the design and analysis method of the acoustic horns with double extrusion to process tube double side flange simultaneously. Repairrefurbish ultrasonic horns reface, retune, replace stud used ultrasonic welders. Sonotrode is the only part of the ultrasonic system, which is unique to each process. Sonotrode design and manufacturing instructions zvei handbook. Design and implementation of a novel singledriven ultrasonic. The present work discusses the design requirements of horns in ultrasonic system.
Optimization design for ultrasonic horn with large amplitude. The considered input parameters were working frequency, maximum crosssectional. Design and analysis of ultrasonic welding horn using finite element analysis v. Solve ultrasonic horn problems with finiteelement analysis. Design and analysis of ultrasonic horns operating in. Ultrasonic welding is the most common application of ultrasonic assembly. Publishers pdf, also known as version of record includes final page, issue and volume numbers. Finite element analysis assisted design of ultrasonic horn. A novel ultrasonic steel horn with a bezier profile is developed.
Sonobond ultrasonics 1, a comparison of wedgereed and lateral drive ultrasonic welding systems pdf, 1191 mcdermott drive, west chester, pa 19380 usa. Albudairi, hassan dakhil 2012 design and analysis of. It plays an important role in ultrasonic vibration aided machining system. Using the relationships from literature and using integrated cadcae applications, the paper presents the design and verification of a horn used on ultrasonic systems for. Ultrasonic transducers are key components in sensors for distance, flow and level measurement as well as in power, biomedical and other applications of ultrasound. Ultrasonic horn design for ultrasonic machining technologies.
Pdf many of industrial applications and production technologies are based on the application of ultrasound. An optimization scheme and finite element analyses are used to design the horn. The ultrasonic booster adjusts the vibrational output from the transducer and transfers the ultrasonic energy to the horn. The ultrasonic horn is used as an element that serves to transfer of the vibration energy from the transducer towards to the tool interacting with workpiece. If you need assistance deciding upon which material to use for your ultrasonic horns, please call industrial ultrasonics. Ultrasonic transducers measurements and horn design youtube. Scaleup design of ultrasound horn for advanced oxidation. Ultrasonic transducers measurements and horn design. The ultrasonic horn, usually onehalf wavelength long at a resonant. M min1 pd dh power density for designed horn w pd th power density for typical horn w ultrasonic horn hta formation rate. The design of acoustic horns for ultrasonic aided tube.
The design of acoustic horns for ultrasonic aided tube double. Reliable performance of such horns is normally decided by the uniformity of. Ultrasonic splicing system ultrasonic welding 2032s the 2032s is a fullrange ergonomic wire splicing system to produce highquality splices at the lowest cost operation. The simplest example is the axialmode halfwavelength sonotrode. Ultrasonic horns are tuned components designed to vibrate in a longitudinal mode at ultrasonic frequencies. The generator features a keypad or buttons which allow. Ultrasonic horn design using sonoanalyzer a basic guide. Sonotrodes ultrasonic horns and boosters are special tools designed so that their natural vibrations resonance form a defined mode shape at a particular frequency. In order to obtain the exact resonant frequency of the horn. In this work we present a novel approach to the design a longitudinaltorsional lt ultrasonic horn which adapts the front mass in a traditional langevin transducer. Research and design of ultra long ultrasonic horn crimson. Jayaraj 3 1, 2, 3 department of mechanical engineering.
In ultrasonic welding, design of horn is one of the most important steps. The ultrasonic generator converts input ac supply into high frequency electrical mechanical energy. The amplification factor, the numerical calculation and the finite element analysis are applied to the design of the horn. Us generator, converter and horn also known as a probe. The first longitudinal displacement mode of the horn is exploited for high displacement amplification. The ultrasonic horn then contacts and delivers power to the load. Information about the openaccess article ultrasonic horn design for ultrasonic machining technologies in doaj. Optimization design for ultrasonic horn with large. I was able to measure the peaktopeak displacement of my ultrasonic horn. The considered input parameters were working frequency, maximum crosssectional area.
Introduction the ultrasonic horn or sonotrode that will be simulated is a part of a vibratory apparatus used for experimental research cavitation erosion of materials. The principal function of the horn is to amplify the amplitude of ultrasonic vibration of the tool to the level required to the effective machining. Ultrasonic horn measuring vibration amplitude youtube. Solve ultrasonic horn problems with finiteelement analysis computer modeling with 3d finiteelement analysis fea is used in the plastics industry because it can identify stresses, predict performance, and analyze part failures that can often be missed by traditional 2d modeling methods. Using the relationships from literature and using integrated cadcae applications, the paper presents the design and verification of a horn used on ultrasonic systems for welding cables for the automotive industry. Based on genetic algorithm, the horn with large vibration amplitude ratio was. Design and analysis of slotted horn for ultrasonic plastic. In welding, the horn is brought into contact with one of the workpieces, pressure is applied and vibrating ultrasonic energy travels through the material, generating frictional heat at the joint area between the two parts. A composite horn is actually a halfwave coupler horn with two or more halfwave, tuned horns attached to it. Piezoelectric transducer design ultrasonic resonators. The paper deals with study through finite element method fem of ultrasonic stepped horn.
Design and manufacture of plastic welding horns sonotrodes. A series of design and analysis of the ultrasonic horn have been carried out to improve the performance. Horns are usually made of titan alloy ti6al4v because of its excellent characteristics in sound transportation. We design and manufacture high quality ultrasonic welding horns and fixtures for use on all brands of ultrasonic welders. The ultrasonic horn was seen as a kind of finitelength tube with continuously variable section. Specialist test equipment is required at least a horn analyser capable of driving the sonotrode over a range of frequencies and measuring its response.
The three major parts of the usdc, namely, the ultrasonic actuator, the free mass, and the drill bit, are being optimized to address the efficiency and drilling rate issue. With the functions of amplitude amplification, impedance matching and protecting the transducer in ultrasonic machining system, ultrasonic horn is an important component in design of power ultrasonic vibration system. In this paper, a longitudinal wave horn with 12 wavelengths is taken as. Part one provides an overview of materials and design of ultrasonic. Factors which influence the horn design are the materials to be welded and the method of assembly. The booster also generally provides a method for mounting the ultrasonic stack to a support structure. Nov 01, 2006 solve ultrasonic horn problems with finiteelement analysis computer modeling with 3d finiteelement analysis fea is used in the plastics industry because it can identify stresses, predict performance, and analyze part failures that can often be missed by traditional 2d modeling methods. Horn design for ultrasonic vibrationaided equal channel. Simulation, ultrasonic horn, materials, natural frequency. Ultrasonic horn design for ultrasonic machining technologies m. Pdf design and analysis of ultrasonic welding horn using. Ultrasonic vibration hot embossing and ultrasonic welding techniques provide a fast and reliable method to fabricate encapsulated oring. There are many different horn shapes and styles depending upon the process requirements. An optimization method of the vibrating horns is presented considering the smallest action principle and the attached cutting tool mass.
A sonicator system is comprised of 3 major components. Given that sectional area of ultrasonic horn is the function of the coordinate x. Design and analysis of horn profiles for ultrasonic welding is modeled using finite element analysis fea. Ultrasonic horn design using sonoanalyzer a basic guide first principles. The dynamical properties of different geometrical shapes of ultrasonic horns are presented in this paper. Pdf ultrasonic horn design for ultrasonic machining technologies.
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