Design and performance analysis of ultrasonic horn with a longitudinally changing rectangular cross section for USM using finite element analysis

Jagadish, Jagadish; Ray, Amitava

doi:10.1007/s40430-018-1281-7

Cited by 19 publications

(9 citation statements)

References 11 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Roopa Rani et al studied the displacement, stress, and heat specification of various horns with different cross-sectional shapes through experimental and analytical methods, and Nguyen et al developed a horn with a B-spline cross-sectional shape and further investigated its characteristics [16,17]. In addition, many researchers have investigated the displacement and frequency characteristics of various ultrasonic machines considering the geometrical characteristics of the horn, but it was a single-material ultrasonic horn and blade, and they did not even consider the various geometrical design variables simultaneously [7,[18][19][20][21][22][23][24][25][26].…”

Section: Conceptual Design Of a Sonotrodementioning

confidence: 99%

Optimal Design and Experimental Verification of Ultrasonic Cutting Horn for Ceramic Composite Material

et al. 2021

View full text Add to dashboard Cite

We developed and optimized a block-type ultrasonic horn that can be used for cutting hard materials. The proposed block-type sonotrode consists of an aluminum horn and a tungsten carbide blade to increase the cutting of hard materials. We designed an initial ultrasonic block horn that has double slots and an exponential stepped profile. We developed a finite element model of the initial model and analyzed the characteristics of natural frequency and displacement. We formulated a DOE table and response surface to perform sensitivity analysis and analyze the correlation between the design variables and characteristics of the proposed block horn. The optimal ultrasonic block horn was derived via a multi-objective optimal design problem to maximize the amplitude uniformity of the proposed horn and frequency separation. We fabricated the optimal block horn and verified it experimentally. An ultrasonic cutting experiment was conducted to find the ultrasonic cutting force with hard ceramic composite materials. A cutting test with a conventional cutting machine under the same condition was also conducted to compare the cutting force. The proposed optimal ultrasonic cutter requires 70% less cutting force than the conventional cutter to cut a ceramic composite material and the cutting surface with the application of the proposed optimal ultrasonic cutter is much cleaner with no crack and delamination than that with the application of the conventional cutter.

show abstract

Section: Conceptual Design Of a Sonotrodementioning

confidence: 99%

Optimal Design and Experimental Verification of Ultrasonic Cutting Horn for Ceramic Composite Material

et al. 2021

View full text Add to dashboard Cite

show abstract

“…Generally, the ultrasonic horn used for research and industrial applications have circular cross section for smooth connection and energy transfer. Jagadish et al analyzed the influence of rectangular cross section on the performance of exponential horn and compared with that of circular cross section [41]. Researchers has integrated the exponential profile with cylindrical, step and conical profiles and investigated the performance of ultrasonic system [41,43,[53][54][55]59].…”

Section: Exponential Hornmentioning

confidence: 99%

“…The performance of ultrasonic horn with cross section was observed to be better as compared to that having circular rectangular cross section in terms of vibration amplification and stresses. Jagadish et al also investigated the performance of cylindrical-exponential horn with rectangular cross section and observed the performance better as compared to similar design with circular cross section [41]. Since the cross section of transducers and ultrasonic tool are circular, therefore rectangular horns are not preferred for smooth transfer of ultrasonic energy.…”

Section: Cylindrical-exponential Hornmentioning

confidence: 99%

“…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]. 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.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

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

View full text Add to dashboard Cite

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.

show abstract

“…The method of ultrasonic depends on the abrasion phenomenon. Blows from the grains of the harder abrasion, brittle materials are removed [4][5][6]. Abrasion phenomenon is under curb of the tool, which regularly vibrates with low amplitude (5-75 µm) and feed [1].…”

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.

View full text Add to dashboard Cite

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.

show abstract

Design and performance analysis of ultrasonic horn with a longitudinally changing rectangular cross section for USM using finite element analysis

Cited by 19 publications

References 11 publications

Optimal Design and Experimental Verification of Ultrasonic Cutting Horn for Ceramic Composite Material

Optimal Design and Experimental Verification of Ultrasonic Cutting Horn for Ceramic Composite Material

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

Contact Info

Product

Resources

About