Design and Analysis of Slotted Horn for Ultrasonic Plastic Welding

Abstract

Ultrasonic horns are tuned components designed to vibrate in a longitudinal mode at ultrasonic frequencies. 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 non-tuned modes at the operating frequency. In order to maximise vibration amplitude uniformity, standard slotting configurations are included in the horn design. In this work the slot position in the horn is optimised using factorial design of experiments and the mathematical model developed is further interfaced with genetic algorithm. Modal and harmonic analysis of the horn is done using ANSYS software package. It is observed that slotted block horn with optimised slot position vibrates in longitudinal mode with uniform displacement amplitude across the face of the sonotrode.

Design and Optimization of Slotted Block Horn Utilized in Ultrasonic Insertion Process Through Rsm-fea-ga Integration Technique

“…From harmonic analysis, maximum displacement amplitude obtained at the output face of block horn is 29.6 µm (Table 4). It is also observed that the uniformity of displacement amplitude is 100% at output face of horn which is in good indenture with previous studies Dipin Kumar et al [8]. Figures 13 and 14 show the von-Mises stress measured in the slotted block horn.…”

“…The vibrations are longitudinal and the output face slotted block horn is perfectly flat which is highly desirable for ultrasonic multiple insertion. This significance is well connected with the results detailed by Dipin Kumar et al [8]. So, all the profiles of the slotted block horns are valid for performing harmonic analysis.…”

“…Dipin kumar et al [8] designed and analyzed slotted horn for ultrasonic plastic welding through FEA, factorial design and genetic algorithm. Modal and harmonic analyses were performed as per full factorial design.…”

“…This frequency is within the operating frequency of ultrasonic insertion machine. Also, it was observed that the vibration is purely in longitudinal direction and output face of block horn is perfectly flat which is highly desirable design objective of the slotted block horn [8]. The harmonic analysis results of optimum design of block horn are shown in Thermal analysis was performed on ABS thermoplastic electrical switch box to find the temperature at joint and also to check the dimensional stability of mounting hole during ultrasonic insertion process.…”

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

“…The stresses in cylindrical, conical, Gaussian, exponential and catenoidal horn designs are very low, but the amplitude of vibration at the tool end is also extremely less as compared to the step design [6,10,13,20,31,32]. Slots and holes have been incorporated in some horn designs to increase the amplitude of vibration and reduce stresses [7,26,[33][34][35][36][37][38][39][40]. 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].…”