An analytical approach to design horns and boosters of ultrasonic welding machines
Abstract This paper presents a new design approach for two main components of an ultrasonic plastic welding machine, booster and horn, based on an analytical model. The design procedure is developed due to the lack of a comprehensive and precise analytical model for rapid design and analysis of thes...
| Main Authors: | , |
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| Format: | Article |
| Language: | English |
| Published: |
Springer
2022-05-01
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| Series: | SN Applied Sciences |
| Subjects: | |
| Online Access: | https://doi.org/10.1007/s42452-022-05044-6 |
| Summary: | Abstract This paper presents a new design approach for two main components of an ultrasonic plastic welding machine, booster and horn, based on an analytical model. The design procedure is developed due to the lack of a comprehensive and precise analytical model for rapid design and analysis of these components. The previous analytical models use the one-dimensional wave equation that causes significant errors in designing components with large lateral dimensions. Three-dimensional vibrations are considered for developing an analytical model using the apparent elasticity method. In this way, longitudinal frequency equations are coupled with radial frequency equations by mechanical coupling coefficients. Also, the damping of materials is taken into account. The model can be adapted to calculate the resonant length of the components or calculate the resonant frequency. To verify the model, the results are compared to a numerical simulation. The difference between analytical and numerical resonance frequency is less than 0.02%. Moreover, an experimental modal analysis is performed, which shows 0.9% error with analytical results. Article highlights A new design approach for boosters and horns has been developed based on an analytical model. Three-dimensional vibrations are considered in the model using the apparent elasticity method. The accuracy of calculating resonant frequencies is more than one-dimensional design method. |
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| ISSN: | 2523-3963 2523-3971 |