Analysis of the dynamic performance of a complex ultrasonic horn for application in friction stir welding

Kumar, Sachin; Ding, Wei; Sun, Zhongyue; Chen, Wu

doi:10.1007/s00170-018-2003-0

Cited by 40 publications

(17 citation statements)

References 29 publications

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“…Research methodology, numerical computations and performance of ultrasonic horns were validated with research of Wang et al, Rani et al, Roy et al, Kumar et al, and Pang et al by developing the geometric models of standard ultrasonic horns based on their dimensions and conducting finite element analysis for the determination of resonant frequency, vibration amplitude and stresses [7,12,15,40,57,59]. Finally, those ultrasonic horns were preferred which provided greater vibration amplification, low stresses and higher operating life.…”

Section: Methodsmentioning

confidence: 99%

“…Kumar et al designed multistep conical ultrasonic horn for ultrasonic vibration assisted friction stir welding using finite element analysis [57]. They used modal analysis to determine the mode shapes and associated modal frequencies, whereas harmonic analysis to determine magnification factor and equivalent stresses.…”

Section: Multistep Conical Hornmentioning

confidence: 99%

“…1) [4,5] consists of ultrasonic generator, piezoelectric transducer, mechanical horn and cutting tool. The ultrasonic generator converts low frequency (50)(51)(52)(53)(54)(55)(56)(57)(58)(59)(60) signal to high frequency (more than 20…”

Section: Introductionmentioning

confidence: 99%

“…The lengths and diameters of the cylindrical portions, cross sectional shape (circular to rectangular) [41] and the location of mountings has also been varied to optimize and improve the performance of ultrasonic horn [42][43][44]. Hybrid horns, which are combination of basic horn profiles such as multi-step [45,46], cylindrical-conical / step-conical [31,36,39,43,44,[47][48][49][50][51][52], double conical [6,53], step-exponential / cylindrical-exponential [43,44,[53][54][55], multistep conical [56,57], step-catenoidal [54], step-Gaussian / cylindrical -Gaussian [58] and cylindrical-conical-exponential [59] have also been designed and analyze to assess horn performance. Other horn designs have also been attempted in order to improve the amplitude of vibration while keeping the stresses in acceptable limits [33,[60][61][62][63][64].…”

Section: Introductionmentioning

confidence: 99%

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Numerical Evaluation of State of the Art Horn Designs for Rotary Ultrasonic Vibration Assisted Machining of Nomex Honeycomb Composite

Mughal

Qureshi

Qaiser

et al. 2021

Preprint

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Ultrasonic horn plays vital role in achieving vibration amplitude suitable for efficient machining of advanced composites. Due to very high operating frequency of at least of ultrasonic machining system, horn may be subjected to high stresses leading to failure. Mechanical horn is designed to get optimum vibration amplification while keeping stresses in acceptable limits. In this research, state of the art ultrasonic horns were designed with same length and diameters at the transducer side and tool ends under similar operating conditions. All standard and hybrid ultrasonic horns, including some new designs, suitable for machining applications were evaluated through finite element analysis. Modal analysis was performed for computing axial modal frequencies, whereas harmonic analysis was carried out to determine vibration amplitude, stresses and factor of safety. The performance of state of the art ultrasonic horn designs were later compared in terms of vibration amplification, stresses and operating life. The axial modal frequency and amplitude of vibration achieved by barrel, cylindrical-double conical and hollow exponential horns were observed to be greater as compared to the step horn, however the former were prone to greater stress concentrations and low operating life. Reasonably higher vibration amplification, factor of safety and low stresses were achieved by Bezier, cylindrical-catenoidal, cylindrical-Bezier, step-conical, step-catenoidal, step-Bezier, double conical, multistep and multistep-conical horn designs. Remarkably, circular hollow exponential and multistep-conical ultrasonic horns were observed to achieve vibration amplification, factor of safety and operating life higher than that of commercially available step horn.

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Section: Methodsmentioning

confidence: 99%

Section: Multistep Conical Hornmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Numerical Evaluation of State of the Art Horn Designs for Rotary Ultrasonic Vibration Assisted Machining of Nomex Honeycomb Composite

Mughal

Qureshi

Qaiser

et al. 2021

Preprint

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“…Therefore, the natural frequency of the horn as the main part of the vibration set-up has been numerically and experimentally obtained using the modal analysis. Kumar et al [17] have attempted to carry out a detailed design analysis of simple and complex horns in order to minimize the failure of horn attachments and maximize ultrasonic energy utilization. Razavi et al [18] have suggested that for the calculation of the natural frequency and amplification factor the numerical analysis and analysis of free vibrations have initially performed with simple geometry for a five-element horn.…”

Section: Introductionmentioning

confidence: 99%

Design of Bezier profile horns by using optimization for high amplification

Kumar

Yadava

Patel

2020

J Braz. Soc. Mech. Sci. Eng.

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Rotary ultrasonic machine (RUSM) has a lot of applications in industries, with the recent uses of stronger and harder materials. Machining performance of RUSM depends on the design of the horn. A horn also known as a tool holder or concentrator is a waveguide focusing device, which has a decreasing area of the cross section from the upper to lower end. In RUSM, the high amplification factor of the horn is required to increase tooltip vibration for getting a high material removal rate. In this study, the design of the horn using an optimization procedure and finite element analysis (FEA) has been done. FEA-based MATLAB code has been developed for finding all the stress components, axial amplitude, and resonance frequency. Results are validated from the experimental data available in the literature, and it has been found that it is in good agreement with the literature. The amplifications of the horns with cubic and quadratic profiles 23.8% and 19%, respectively, are higher than the traditional horn with the same length and diameters of the ends. Stresses at different locations have been found within the allowable endurance limit. The effect of frequency on the stress distribution has also been studied and found that the variation of stresses over the domain of horn increases with an increase in frequency, but the value of stress is much lower at the resonance frequency.

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Ultrasound Added Additive Manufacturing for Metals and Composites: Process and Control

Kumar

Kishor

2021

Springer Series in Advanced Manufacturing

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Analysis of the dynamic performance of a complex ultrasonic horn for application in friction stir welding

Cited by 40 publications

References 29 publications

Numerical Evaluation of State of the Art Horn Designs for Rotary Ultrasonic Vibration Assisted Machining of Nomex Honeycomb Composite

Numerical Evaluation of State of the Art Horn Designs for Rotary Ultrasonic Vibration Assisted Machining of Nomex Honeycomb Composite

Design of Bezier profile horns by using optimization for high amplification

Ultrasound Added Additive Manufacturing for Metals and Composites: Process and Control

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