The gain of the ultrasonic horn is determined by its profile. We design and manufacture high quality ultrasonic welding horns and fixtures for use on all brands of ultrasonic welders. A novel ultrasonic steel horn with a bezier profile is developed. Ultrasonic horn design for ultrasonic machining technologies. Optimization design for ultrasonic horn with large. Cad cae applications, the paper presents the design and verification of a horn used on ultrasonic systems for welding. The ultrasonic horn, usually onehalf wavelength long at a resonant. The ultrasonic horn was redesigned utilizing fea design software. The magnification factor for the amplitude of vibration is dependent on the design of the ultrasonic horn. Ul trasonic horn transfers the longitudinal ultrasonic waves from the transducer end to the toe end with attached the cutting tool and it ampli. Pdf ultrasonic horn design for ultrasonic machining technologies.
Precision ultrasonic welding horn design sonotrode horn. First the dimensions are obtained through commercial sonotrode design software. Our company is dealing with ultrasonic welding equipment. 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. This software is especially useful in controlling even face amplitude in large or irregular shaped horns. The following catalog is designed to help simplify the selection and ordering of ultrasonic horns through general descriptive information, illustrations and tabular data. Ultrasonic transducer horn ultrasonic horn design guidelines. Ultrasonic welding horns for welding thermoplastic materials. Ultrasonic transducers measurements and horn design.
An ultrasonic horn also known as acoustic horn, sonotrode, acoustic waveguide, ultrasonic probe is dwindling bar of metal which is, usually, used for enlarging amplitude of oscillation displacement in. Computer aided resonator design card is software that applies quantitative techniques to the design of ultrasonic resonators horns, boosters, and. The design of ultrasonic horn is utmost important because incorrect design not only. Design and manufacture of plastic welding horns sonotrodes.
The resonators are designed using finite element analysis fea simulation software. Manufacture of ultrasonic welding horns should be left to the ultrasonic welding equipment manufacturer who will design the horn to match both the frequency of their equipment and the profile of the. Ultrasonic horns and boosters selection guide engineering360. The booster also generally provides a method for mounting the ultrasonic stack to.
Considering the facilities of the matlab software, a power function was defined. Powerultrasonics sonotrode design analysis software. 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. However, the interaction with tool end vibrations deteriorates the horn performance. The most important aspect of sonotrode design is a sonotrode resonant frequency. Optimization of the longitudinaltorsional ultrasonic step. The mathematical equations are developed for analyzing vibration system to determine the displacement and stresses. To use fea software to analyze the failing horn and diagnose the problem, we first measured the horn and created corresponding cad files as if we were first designing the horn. Optimization design for ultrasonic horn with large amplitude based.
The design of acoustic horns for ultrasonic aided tube. Most major ultrasonic manufacturers now employ horn design software. Solve ultrasonic horn problems with finiteelement analysis. An optimization scheme and finite element analyses are used to design the horn. In the present work, an ultrasonic circular hollow horn is designed for usm using finite element.
Design of a circular hollow ultrasonic horn for usm using. Axialmode refers to the predominant direction of vibrational movement along the axis of the sonotrode. Branson ultrasonic horn acoustical tool adapter ebay. When i worked at my last company before setting up on my own the toolroom made a lot of ultrasonic horns. The displacement amplification and stress distribution. Factors which influence the horn design are the materials to be welded and the method of assembly. Precision ultrasonic welding horn design sonotrode horn for different application. Ultrasonic booster design, ultrasonic horn for ultrasonic. This paper discusses design of conical, exponential and stepcylindrical horn for ultrasonic machining. My webpage on this proved to be reasonably popular. Standard horns listed in the catalog are compatible with most of todays ultrasonic welding equipment. Using finite element analysis finite element analysis fea software, each weld horn is analyzed in the most detailed and optimized. Horns are usually made of titan alloy ti6al4v because of its excellent characteristics in sound transportation.
Computeraided design technology to design ultrasonic tooling. Strain gauges have proven their value in the electrical measurement of mechanical quantities and play a. The issues involved in the study of design are horn material and shape. Sonotrodes ultrasonic horns and boosters are special tools designed so that their natural vibrations resonance form a defined mode shape at. 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. We not sale ultrasonic horn alone, we produce it for our own equipment only. Applied and computational mechanics 4 2010 7988 ultrasonic horn design for ultrasonic machining technologies m. Further enhancements include finite element analysis of horns. Ultrasonic horn design using sonoanalyzer a basic guide. Design requirement includes amplitude required at the tool end and minimal stress distribution throughout the horn while subjected to loading. Computer aided resonator design card is software that applies quantitative techniques to the design of ultrasonic resonators horns, boosters, and transducers that vibrate in a longitudinal mode. The aim of this paper is to design and fabricate a horn for ultrasonic aided tube flange making by employing comosol finite element software.
Cylindrical, conical and exponential horns are analysed for their behaviour. The simplest example is the axialmode halfwavelength sonotrode. This paper performs the analysis and design of acoustic horns for ultrasonic welding of plastic material, utilizing ansys finite element software. 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. Ultrasonic transducers are key components in sensors for distance, flow and level measurement as well as in power, biomedical and other applications of ultrasound. The main aim is for me to tune the horn to match the frequency of the transducer which is 40 khz, i am trying to simulate this in sw. In ultrasonic welding, design of horn is one of the most important steps. Sonotrodes ultrasonic horns and boosters are special tools designed so that their natural vibrations resonance form a defined mode shape at a particular frequency. An optimization method of the vibrating horns is presented considering the smallest action principle and the attached cutting tool mass. Over the years, industry has attempted to standardize horn design, however, its this writers opinion that a custom designed horn, tailored to the exact specification of the application is always the best bet. The first longitudinal displacement mode of the horn is exploited for high displacement amplification. Reliable performance of such horns is normally decided by the uniformity of. The model is based on websters wave propagation equation and as.
Design and development of sonotrode for ultrasonic drilling. Krell engineering consults in the design of ultrasonic resonators horns. I would like to know if you can recommend proved software for sonotrode design. Specialist test equipment is required at least a horn analyser capable of driving the sonotrode over a range of frequencies and measuring its response. 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. Modal analysis of ultrasonic horn using finite element method. Design, manufacturing, and testing phases are meticulously documented. Applications range from interior components side door trim, center console to engine compartment components cylinder. Krell engineering consults in the design of custom ultrasonic resonators ultrasonic horns sonotrodes probes, boosters, transducers converters for frequencies between 10 khz and 100 khz. Ultrasonic horns are designed with an fea finite element analysis simulation program that allows our engineers to observe the vibratory action of the horn prior to fabrication.
Krell engineering design of ultrasonic resonators, ultrasonic horns. I am attempting to design, tune and simulate an ultrasonic horn sonotrode for the purpose of vibrating a material for enhanced compaction. Sonotrode design software powerultrasonics sonicdiagnostic. Combining modes of vibration, such as longitudinal and torsional vibration, is advantageous in many ultrasonic applications such as ultrasonic drilling, welding, and motors. As you can see in figure 2 redesigned ultrasonic horn, the amplitude is now evenly distributed across the entire face. Ultrasonic horns are axisymmetric devices that provide, with high efficiency. Patsonics manufactures ultrasonic horns from different raw materials based upon acoustical and mechanical properties and your specific application needs. For proper concentration of ultrasonic energy across work piece surface during welding, geometry of horn plays a vital role. Sonotrode design is key to success of ultrasonic welding. A problem that is associated with the horns design refers to the shape optimization. Branson lpt low power ultrasonic system 14921026 with 402 converter 500w. Design and analysis of ultrasonic horns operating in.
1546 638 646 1325 176 219 1623 1496 448 21 1123 439 516 247 213 311 140 736 916 1314 1543 234 907 1487 1609 726 1543 1309 767 188 406 290 1219 71 824 1279 941 781 923