Experimental Verification and Design Guidelines for Efficient Ultrasonic Power Transfer Using Capacitive Parametric Ultrasonic Transducers

Wei, Charles; Surappa, Sushruta; Degertekin, F. Levent

doi:10.1109/ius46767.2020.9251408

Cited by 1 publication

(1 citation statement)

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“…This condition ensures that mechanical vibrations are transmitted smoothly from one section to the next without significant reflection or energy loss [28]. To achieve this continuity, several factors must be carefully evaluated during the design and testing of the ultrasonic stack such as Material compatibility, Frequency alignment, Geometric continuity, Mechanical Impedance matching, FE Analysis and experimental testing of the whole stack to check the amplitude uniformity [29].…”

Section: Ultrasonic Horn Designmentioning

confidence: 99%

Design optimization and experimental verification of ultrasonic stack for micro hot embossing of polymers

Abdel-Aleem,

Fath El-Bab,

Yoshino

et al. 2024

J. Micromech. Microeng.

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Ultrasonic micro hot embossing (UMHE) is a prominent technique used in numerous sectors to produce micro parts since it is cheaper, faster, and more accurate. Amplitude uniformity is a crucial parameter in UMHE in order to manufacture micro parts with accurate dimensions and high-quality surfaces, even though limited research has been conducted on the uniformity of ultrasonic amplitude at the horn face during the embossing process. This paper presents an experimental and numerical study for designing an ultrasonic transducer and horn tailored to the micro hot embossing of polymer micro parts. A finite element (FE) simulation model combined with the Taguchi method has been developed to optimize the horn geometry and maximum amplitude uniformity. The Taguchi orthogonal array of 25 design runs has been generated and simulated using the developed FE modal analysis model, and then the optimized geometry was used to fabricate the horn. Applied torque and operating time calibrate and evaluate the transducer vibration characteristics. Experimental and simulation results revealed that the fabricated ultrasonic transducer and horn of a straight microfeature has a natural frequency of 28.8 kHz and has an 11 µm average peak-to-peak amplitude with 0.963 amplitude homogeneity along the microfeature face. The achieved frequency separation was greater than 0.85 kHz, whereas the gain ratio was 1.2. The design methodology developed in this paper showed great potential and has been numerically validated for various microfeature shapes across the horn face. Consequently, it can be applied to various ultrasonic applications beyond UMHE.

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Section: Ultrasonic Horn Designmentioning

confidence: 99%