Design and development of sonotrode for ultrasonic drilling. Specialist test equipment is required at least a horn analyser capable of driving the sonotrode over a range of frequencies and measuring its response. Design and manufacture of plastic welding horns sonotrodes. Computer aided resonator design card is software that applies quantitative techniques to the design of ultrasonic resonators horns, boosters, and. Applications range from interior components side door trim, center console to engine compartment components cylinder. Patsonics manufactures ultrasonic horns from different raw materials based upon acoustical and mechanical properties and your specific application needs. The design of acoustic horns for ultrasonic aided tube. Ultrasonic horns are axisymmetric devices that provide, with high efficiency. Ultrasonic horns are used in the ultrasonicassisted milling and cutting tools.
Ultrasonic transducers are key components in sensors for distance, flow and level measurement as well as in power, biomedical and other applications of ultrasound. An optimization scheme and finite element analyses are used to design the horn. Optimization design for ultrasonic horn with large amplitude based. Powerultrasonics sonotrode design analysis software. We design and manufacture high quality ultrasonic welding horns and fixtures for use on all brands of ultrasonic welders. In ultrasonic welding, design of horn is one of the most important steps. Design of a circular hollow ultrasonic horn for usm using. Ul trasonic horn transfers the longitudinal ultrasonic waves from the transducer end to the toe end with attached the cutting tool and it ampli.
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. When i worked at my last company before setting up on my own the toolroom made a lot of ultrasonic horns. However, the interaction with tool end vibrations deteriorates the horn performance. For proper concentration of ultrasonic energy across work piece surface during welding, geometry of horn plays a vital role. First the dimensions are obtained through commercial sonotrode design software. The ultrasonic horn, usually onehalf wavelength long at a resonant. Computeraided design technology to design ultrasonic tooling. 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. Reliable performance of such horns is normally decided by the uniformity of. Question asked by anderson sinaga on nov 22, 2010 latest reply on oct 5. My webpage on this proved to be reasonably popular.
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. Sonotrodes ultrasonic horns and boosters are special tools designed so that their natural vibrations resonance form a defined mode shape at. The booster also generally provides a method for mounting the ultrasonic stack to. Most major ultrasonic manufacturers now employ horn design software. Further enhancements include finite element analysis of horns. Ultrasonic transducer horn ultrasonic horn design guidelines. 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. Factors which influence the horn design are the materials to be welded and the method of assembly. The stress plot a direct output from the finite element program opens in a new tab.
Cylindrical, conical and exponential horns are analysed for their behaviour. An optimization method of the vibrating horns is presented considering the smallest action principle and the attached cutting tool mass. Ultrasonic horn design using sonoanalyzer a basic guide. Axialmode refers to the predominant direction of vibrational movement along the axis of the sonotrode. 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.
In the present work, an ultrasonic circular hollow horn is designed for usm using finite element. 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. 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. The simplest example is the axialmode halfwavelength sonotrode. Ultrasonic booster design, ultrasonic horn for ultrasonic.
As you can see in figure 2 redesigned ultrasonic horn, the amplitude is now evenly distributed across the entire face. With the improvement of finite element method and the development of correlative software, it is possible to design ultrasonic horn easily with computer. Combining modes of vibration, such as longitudinal and torsional vibration, is advantageous in many ultrasonic applications such as ultrasonic drilling, welding, and motors. I am attempting to design, tune and simulate an ultrasonic horn sonotrode for the purpose of vibrating a material for enhanced compaction. Strain gauges have proven their value in the electrical measurement of mechanical quantities and play a. Using finite element analysis finite element analysis fea software, each weld horn is analyzed in the most detailed and optimized. Precision ultrasonic welding horn design sonotrode horn. 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. The model is based on websters wave propagation equation and as. Design and analysis of ultrasonic horns operating in.
The displacement amplification and stress distribution. The first longitudinal displacement mode of the horn is exploited for high displacement amplification. Sonotrode design is key to success of ultrasonic welding. Powerultrasonics is an independent resource for all users and manufacturers of power ultrasonic and sonochemistry equipment. Sonotrodes ultrasonic horns and boosters are special tools designed so that their natural vibrations resonance form a defined mode shape at a particular frequency. Sonotrode design software powerultrasonics sonicdiagnostic. Krell engineering design of ultrasonic resonators, ultrasonic horns. Design requirement includes amplitude required at the tool end and minimal stress distribution throughout the horn while subjected to loading. This paper performs the analysis and design of acoustic horns for ultrasonic welding of plastic material, utilizing ansys finite element software. The aim of this paper is to design and fabricate a horn for ultrasonic aided tube flange making by employing comosol finite element software. 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. The following catalog is designed to help simplify the selection and ordering of ultrasonic horns through general descriptive information, illustrations and tabular data.
The fem modelling and calculation of modal properties was done using the software. 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. This paper discusses design of conical, exponential and stepcylindrical horn for ultrasonic machining. Krell engineering consults in the design of ultrasonic resonators horns. 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. Modal analysis of ultrasonic horn using finite element method. The gain of the ultrasonic horn is determined by its profile. 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. Horns are usually made of titan alloy ti6al4v because of its excellent characteristics in sound transportation. Precision ultrasonic welding horn design sonotrode horn for different application. Solve ultrasonic horn problems with finiteelement analysis. Ultrasonic horns and boosters selection guide engineering360.
The most important aspect of sonotrode design is a sonotrode resonant frequency. Pdf ultrasonic horn design for ultrasonic machining technologies. Sonotrodes ultrasonic horns and boosters are special tools designed so that their natural vibrations resonance form a defined. The magnification factor for the amplitude of vibration is dependent on the design of the ultrasonic horn. Ultrasonic welding horns for welding thermoplastic materials. Ultrasonic welding is widely used in the automotive industry. The resonators are designed using finite element analysis fea simulation software. The design of ultrasonic horn is utmost important because incorrect design not only. We not sale ultrasonic horn alone, we produce it for our own equipment only. The mathematical equations are developed for analyzing vibration system to determine the displacement and stresses. A problem that is associated with the horns design refers to the shape optimization. Optimization of the longitudinaltorsional ultrasonic step. Ultrasonic transducers measurements and horn design. Branson ultrasonic horn acoustical tool adapter ebay.
Ultrasonic horns ultrasonic horns welders fixtures branson. Standard horns listed in the catalog are compatible with most of todays 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. The ultrasonic horn was redesigned utilizing fea design software. The ultrasonic booster adjusts the vibrational output from the transducer and transfers the ultrasonic energy to the horn. I would like to know if you can recommend proved software for sonotrode design. This software is especially useful in controlling even face amplitude in large or irregular shaped horns. Cad cae applications, the paper presents the design and verification of a horn used on ultrasonic systems for welding. The issues involved in the study of design are horn material and shape. Design, manufacturing, and testing phases are meticulously documented. A novel ultrasonic steel horn with a bezier profile is developed.
462 466 1559 424 1182 1201 791 536 808 15 399 834 288 455 672 636 254 378 1448 42 517 624 1110 1467 1240 857 1383 1184 1030 794 440 155 1092 1545 1049 655 936 211 530 579 16 881 565 906 1107 519 51