Abstract
In this study, dynamic characteristic of stepped horn profile is investigated theoretically and experimentally in terms of natural frequency, displacement amplitude, stress induced and heat developed at joint interface for improving the performance of ultrasonically fastened joints. The profile of stepped horn is computationally modelled and temperature obtained at the joint interface is predicted using Finite Element Analysis (FEA). Computationally modelled stepped horn is fabricated with Aluminium Alloy (AA 6351) based on the FEA results and temperature at the joint interface is measured using Data Acquisition System (DAQ). Pullout strength of ultrasonically fastened joints utilizing stepped horn is measured using computerized tensile testing machine. Measured temperature is correlated with pullout strength of joint and the design of stepped horn is validated.
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