Ultrasonic horn design software

An optimization scheme and finite element analyses are used to design the horn. We not sale ultrasonic horn alone, we produce it for our own equipment only. 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. Ultrasonic horns are used in the ultrasonicassisted milling and cutting tools. Sonotrodes ultrasonic horns and boosters are special tools designed so that their natural vibrations resonance form a defined. The issues involved in the study of design are horn material and shape. 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. Ul trasonic horn transfers the longitudinal ultrasonic waves from the transducer end to the toe end with attached the cutting tool and it ampli. The booster also generally provides a method for mounting the ultrasonic stack to. The following catalog is designed to help simplify the selection and ordering of ultrasonic horns through general descriptive information, illustrations and tabular data. The model is based on websters wave propagation equation and as.

Specialist test equipment is required at least a horn analyser capable of driving the sonotrode over a range of frequencies and measuring its response. This paper performs the analysis and design of acoustic horns for ultrasonic welding of plastic material, utilizing ansys finite element software. An optimization method of the vibrating horns is presented considering the smallest action principle and the attached cutting tool mass. The ultrasonic horn, usually onehalf wavelength long at a resonant. The magnification factor for the amplitude of vibration is dependent on the design of the ultrasonic horn. Horns are usually made of titan alloy ti6al4v because of its excellent characteristics in sound transportation. Ultrasonic transducers are key components in sensors for distance, flow and level measurement as well as in power, biomedical and other applications of ultrasound. Ultrasonic horns are axisymmetric devices that provide, with high efficiency. 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. Our company is dealing with ultrasonic welding equipment. Sonotrode design software powerultrasonics sonicdiagnostic. Ultrasonic horn design for ultrasonic machining technologies. The aim of this paper is to design and fabricate a horn for ultrasonic aided tube flange making by employing comosol finite element software. The design of ultrasonic horn is utmost important because incorrect design not only.

Design and manufacture of plastic welding horns sonotrodes. Ultrasonic welding is widely used in the automotive industry. Sonotrodes ultrasonic horns and boosters are special tools designed so that their natural vibrations resonance form a defined mode shape at. Design, manufacturing, and testing phases are meticulously documented.

Powerultrasonics is an independent resource for all users and manufacturers of power ultrasonic and sonochemistry equipment. Modal analysis of ultrasonic horn using finite element method. This paper discusses design of conical, exponential and stepcylindrical horn for ultrasonic machining. Patsonics manufactures ultrasonic horns from different raw materials based upon acoustical and mechanical properties and your specific application needs. Most major ultrasonic manufacturers now employ horn design software. I would like to know if you can recommend proved software for sonotrode design. Design and development of sonotrode for ultrasonic drilling. 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. The simplest example is the axialmode halfwavelength sonotrode.

I am attempting to design, tune and simulate an ultrasonic horn sonotrode for the purpose of vibrating a material for enhanced compaction. Using finite element analysis finite element analysis fea software, each weld horn is analyzed in the most detailed and optimized. Ultrasonic horn design using sonoanalyzer a basic guide. Question asked by anderson sinaga on nov 22, 2010 latest reply on oct 5. 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. Branson ultrasonic horn acoustical tool adapter ebay. 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.

Axialmode refers to the predominant direction of vibrational movement along the axis of the sonotrode. The stress plot a direct output from the finite element program opens in a new tab. When i worked at my last company before setting up on my own the toolroom made a lot of ultrasonic horns. Branson lpt low power ultrasonic system 14921026 with 402 converter 500w. First the dimensions are obtained through commercial sonotrode design software. Optimization of the longitudinaltorsional ultrasonic step.

For proper concentration of ultrasonic energy across work piece surface during welding, geometry of horn plays a vital role. Reliable performance of such horns is normally decided by the uniformity of. Optimization design for ultrasonic horn with large amplitude based. Standard horns listed in the catalog are compatible with most of todays ultrasonic welding equipment.

Computer aided resonator design card is software that applies quantitative techniques to the design of ultrasonic resonators horns, boosters, and. Ultrasonic horns and boosters selection guide engineering360. Ultrasonic transducers measurements and horn design. 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.

We design and manufacture high quality ultrasonic welding horns and fixtures for use on all brands of ultrasonic welders. A novel ultrasonic steel horn with a bezier profile is developed. Krell engineering consults in the design of ultrasonic resonators horns. The first longitudinal displacement mode of the horn is exploited for high displacement amplification. 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.

Further enhancements include finite element analysis of horns. Cad cae applications, the paper presents the design and verification of a horn used on ultrasonic systems for welding. Strain gauges have proven their value in the electrical measurement of mechanical quantities and play a. In ultrasonic welding, design of horn is one of the most important steps. The ultrasonic horn was redesigned utilizing fea design software. 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. As you can see in figure 2 redesigned ultrasonic horn, the amplitude is now evenly distributed across the entire face. Design requirement includes amplitude required at the tool end and minimal stress distribution throughout the horn while subjected to loading. Ultrasonic welding horns for welding thermoplastic materials. Solve ultrasonic horn problems with finiteelement analysis. The mathematical equations are developed for analyzing vibration system to determine the displacement and stresses. Krell engineering design of ultrasonic resonators, ultrasonic horns. Applied and computational mechanics 4 2010 7988 ultrasonic horn design for ultrasonic machining technologies m. 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 ultrasonic booster adjusts the vibrational output from the transducer and transfers the ultrasonic energy to the horn. Ultrasonic transducer horn ultrasonic horn design guidelines. Ultrasonic booster design, ultrasonic horn for ultrasonic. Pdf ultrasonic horn design for ultrasonic machining technologies.

Design of a circular hollow ultrasonic horn for usm using. Precision ultrasonic welding horn design sonotrode horn for different application. Sonotrodes ultrasonic horns and boosters are special tools designed so that their natural vibrations resonance form a defined mode shape at a particular frequency. 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. Precision ultrasonic welding horn design sonotrode horn.

The design of acoustic horns for ultrasonic aided tube. Design and analysis of ultrasonic horns operating in. Computeraided design technology to design ultrasonic tooling. Combining modes of vibration, such as longitudinal and torsional vibration, is advantageous in many ultrasonic applications such as ultrasonic drilling, welding, and motors. The resonators are designed using finite element analysis fea simulation software. Factors which influence the horn design are the materials to be welded and the method of assembly.

The gain of the ultrasonic horn is determined by its profile. With the improvement of finite element method and the development of correlative software, it is possible to design ultrasonic horn easily with computer. 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. However, the interaction with tool end vibrations deteriorates the horn performance. Considering the facilities of the matlab software, a power function was defined.

This software is especially useful in controlling even face amplitude in large or irregular shaped horns. My webpage on this proved to be reasonably popular. Optimization design for ultrasonic horn with large. Powerultrasonics sonotrode design analysis software. The displacement amplification and stress distribution. 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.