FEM calculation precision manufacturing Ultrasonic sonotrodes

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

Types Of Sonotrodes

Stepped cylindrical – the most common type, cheapest to manufacture, different diameter at each end to provide the required gain.

Exponential cylindrical – development of the above with exponential shape to reduce the stress in the sonotrode, has lower gain capability.

Catenoidal cylindrical – combination of stepped and exponential, reduced stress and moderate gain.

Mother/Daughter – assembly of smaller sonotrodes onto a large block sonotrode to enable a number of sonotrodes to be run on a single system.

Bell – sonotrodes with the centre bored out to provide gain, allows the use of the maximum sonotrode diameter for welding.

Block – rectangular sonotrode, no gain, for welding large flat components.

Blade – rectangular sonotrodes with gain suitable for long or narrow welds.

Slotted – cylindrical, bell, block or blade sonotrodes above certain sizes need to be slotted to eliminate spurious frequencies being developed in sonotrode which would be detrimental to their operation.

The gain in a sonotrode can generally be determined by expressing a comparison of the surface area at the end of the sonotrode as a ratio.

Further information on sonotrodes is given in the sonotrode design section of this course.

Frequently, an ultrasonic horn has a transitional section with a longitudinal cross-section profile that converges towards the output end. Thus, the horn’s longitudinal oscillation amplitude increases towards the output end, while the area of its transverse cross-section decreases. Ultrasonic horns of this type are used primarily as parts of various ultrasonic instruments for ultrasonic welding, ultrasonic soldering, cutting, making surgical tools, molten metal treatment, etc. Converging ultrasonic horns are also commonly included in laboratory liquid processors used for a variety of process studies, including sonochemical, emulsification, dispersing and many others.

In high-power industrial ultrasonic liquid processors, such as commercial sonochemical reactors, ultrasonic homogenizers and ultrasonic milling systems intended for the treatment of large volumes of liquids at high ultrasonic amplitudes (ultrasonic mixing, production of nanoemulsions, solid particle dispersing, ultrasonic nanocrystallization, etc.), the preferred ultrasonic horn type is the Barbell horn.Barbell horns are able to amplify ultrasonic amplitudes while retaining large output diameters and radiating areas. It is, therefore, possible to directly reproduce laboratory optimization studies in a commercial production environment by switching from Converging to Barbell horns while maintaining high ultrasonic amplitudes. If correctly scaled up, the processes generate the same reproducible results on the plant floor as they do in the laboratory.

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.

As sonotrodes wear during extended production, the surface will become marked or pocked. Many times, these marks can be alleviated by the manufacturer so as to extend the life of the sonotrode. However, since the overall length dictates the frequency of vibration, changes in length caused by machining can change the tuning of the sonotrode. Typically, these can be refaced or resurfaced a few times depending on the gain of the sonotrode. Again, this is best left to those with the experience and equipment to do so.

The ultrasonic stack consisting of converter, booster, and sonotrode provides the necessary ultrasonic vibration in order to efficiently and precisely assemble the plastic parts in production. Understanding the terminology used to describe these parts, the way these components interact, and the functions of each will give the user a more thorough understanding of the process and allow for more informed