ultrasonic transducer horn,
ultrasonic cutting horn
The ultrasonic welding horn contains several key acoustic vibration characteristics such as resonance length, amplification factor, strain maximum point, and position of displacement nodes. The most simple and commonly used ultrasonic welding horns are divided into exponential shape, catenary shape, conical shape and stepped shape according to the shape, and they all belong to a single horn. Welding horns should be designed and developed separately for different welding applications. RPS-SONIC has more than ten years of practical experience in ultrasonic design. We can design the corresponding horn according to the welding needs of customers. Then, the natural frequency and modal analysis are performed by the finite element method, and a new horn is designed to meet the functional requirements of effective transmission and uniform distribution of vibration energy. In the design process, combined with the parametric modeling, full factor experimental design optimization (DOE) and probabilistic design system (PDS) modules of ANSYS, the parameter design and robust design are performed, and the geometric size is adjusted so that the natural frequency of the horn matches the ultrasonic frequency The corresponding modal amplitude is uniform on the working surface, which reduces the problem of local structural stress concentration, and has good adaptability to changes in parameters of materials and the environment. The designed tooling is completed and put into use at one time, which avoids the waste of time and cost caused by repeated trimming of the tooling. Through practical cases, the longitudinal vibration theory of a single horn is compared with the actual results of the hornand the finite element analysis. It is verified that the theoretical method is suitable for the design of four types of plastic welding horn with simple cavities. The prepared parameter solution and model drawing program can be used for rapid prototype design of ultrasonic plastic welding horns. Compared with the current ultrasonic plastic welding horns, which rely heavily on finite element analysis and empirical design methods, rapid prototyping methods are more accurate, efficient, and easy to operate.
With the help of the software of the finite element analyzer, the reject rate of the hornis greatly reduced, and the output of the horn is evenly and effectively maximized.
The main issues for ultrasonic welding horn:
1) Uneven amplitude across the face of the horn was causing a weak weld at both ends of the seal area and
2) The horns were cracking and had to be replaced at an unacceptable rate .
Both of these problems are caused by the uneven force on the cross section of the horn. The horn received too much ultrasonic power at a point, which caused cracking. At the same time, too much energy gathers at one point, resulting in insufficient capacity of other parts, low output, and uneven welding. How to effectively avoid this problem requires us to work hard when designing. Using the FEA analyzer, finite element analysis is performed when the horn is designed, and the force on the horn section can be clearly known. The uniform and strong force on the horn section is the ideal state. as the picture shows:
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