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Solving the performance parameters of welding horn
ultrasonic weldind horn
The ultrasonic welding horn is the contact interface between the ultrasonic welding machine and the material. Its main function is to uniformly and effectively transmit the longitudinal mechanical vibration output from the horn to the material. The materials used are usually high-quality aluminum alloys or even titanium alloys. Because the design of plastic materials changes a lot, and the appearance varies widely, the horn also changes accordingly. The shape of the working surface must be well matched with the material, so that the plastic is not damaged during vibration; at the same time, the first-order longitudinal vibration must be coordinated with the output frequency of the welding machine, otherwise the vibration energy will be consumed internally. When the horn vibrates, stress concentration will occur locally. How to optimize these local structures is also a problem to be considered during design.
The forms were compiled and programmed using Microsoft Excel spread sheet software. The basic information that needs to be input when solving includes the working frequency, material, density, Young's modulus, wave velocity, Poisson's ratio, wide-end diameter and narrow-end diameter of the welding horn. Spreadsheets simultaneously solve and feedback exponential, catenary, conical and stepped welding horn with commonly used description parameters such as magnification factor, resonance length, displacement nodes, and locations of stress maxima. The difference between the calculation results of the four types of welding horns with the same initial conditions can be visually identified through the table. More ideal calculation results can be obtained by continuously adjusting the initial conditions (mainly by adjusting the external dimensions and examining the theoretical amplification factor of the horn).
Parameterized drawing of ultrsonic welding horn
In order to meet the needs of further drawing or designing of ultrasonic welding horn, Excel spreadsheets calculate the overall dimensions and key point coordinates of various welding horn, combined with the language rules of Au-toLISP and ANSYS APDL parametric secondary development design software, and automatically compile parameters Modeling program. Enter the modeling program into the command window of AutoCAD and ANSYS engineering design software to complete the plan drawing and 3D modeling of the welding horn, and provide horn drawing or finite element analysis.
The design uses hard aluminum as the horn material, and enters the wide-end diameter D1 and narrow-end diameter D2 for trial and error. Obviously, with the same cross-section dimensions at both ends, the stepped horn is easier to obtain high gain. Determine the horn magnification factor and resonance length for both end face diameters after leaving margin for end face avoidance
Comparison of finite element analysis
Using the ANSYS APDL parametric modeling program obtained in the example, the modal analysis is performed in the AN-SYS environment. The model was meshed with SOLID95 elements, and a total of 9,670 elements and 14,786 nodes were generated, which were solved using Lanczos algorithm. The first-order longitudinal vibration frequency of the horn is f = 20044Hz.
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