FEM calculation precision manufacturing Ultrasonic sonotrodes

We not sale ultrasonic horn alone, we produce it for our own equipment only.

Horn or Sonotrode. The horn is sometimes more commonly referred to as a sonotrode outside the United States. The horn receives vibrations from the booster and further amplifies or attenuates the amplitude of the acoustic waves. The horn is also responsible for applying these vibrations to the parts being welded by direct contact. In a plastic welder, the horn and booster vibrate axially at the operational frequency set by the power supply. The horn contacts the top plastic piece and applies these vibrations perpendicular to the surface of the part. In contrast, metal welder horns lay horizontal, and the vibrations are applied parallel to the parts’ surface. The horn is uniquely engineered to vibrate with its ends moving in opposite directions at all times while the horn’s center stays in place. By multiplying the converter’s output amplitude by the gain of the booster and by the gain of the horn, you can find the stack’s effective output amplitude applied to the part. Titanium is the material of choice for horn construction due to its mechanical properties such as high fatigue strength and hardness, but economical aluminum and steel horns also exist for the right application. There are multitudes of horn shapes that each have their own unique application, and custom horns can be made for special applications. A circular horn for example is useful when the parts are to be welded on their circumference. Before a horn can apply the vibration to the workpiece, it must first be lowered into place.

Actuator. The actuator is responsible for lowering the stack onto the parts to be welded. It must also apply a force consistent with the desired application. Ultrasonic welding actuators are typically pneumatic or electric driven and provide a weld force in the range of 50-750 lbs. Actuators used in metal ultrasonic welder may by driven by hydraulics and see more force. The exact force will be determined based on the design of the parts being welded.

Nest or Anvil. There are typically two parts being welded together—an upper half and a lower half. The lower half sits in a fixture referred to as a nest. The nest will direct the vibrations to the interface between the two parts. When the fixture holding the lower part is more flat, it may be referred to as an anvil. When welding long seams, some machines have a mobile anvil which moves the part along while keeping the welder in place.

The Ultrasonic Welding Process.Now that you know the major components of an ultrasonic welder, it’s time to understand how a typical welding cycle works:
The first step is to load the parts into the nest by hand or by automation—automation is used in high volume runs. Next the controls of the welder will run in one of four modes:

ADVANTAGES:

• Sonotrodes tuned to frequency and amplitude
• Sonotrode geometries and anvil versions to suit any application
• Long service life due to individual selection of the sonotrode material to suit the respective plastic
• Optimal welding results due to precise resonance behavior of the sonotrodes
• Long service life due to FEM calculation of the best resonance behavior
• Stable process with low thermal expansion due to innovative receptor

Standard designs are available in lengths up to 26" long with a 2-1/2" maximum width. All of our horns are designed to vibrate with even amplitude across the entire face at reduced power.

Design by RPS-SONIC and Professional analysis for different application.Horn design is not a simple process. Correct material must be selected, horns must be balanced, designed for the required amplitude, and be accurately tuned to a specific frequency. Incorrectly tuned horns can cause damage to the converter and/or power supply. Branson’s Tooling Engineers use Finite Element Analysis (FEA) to design and optimize horns, for proper tuning, stress level, amplitude level and uniformity.