Computer-Aided Design of Bezier Horns Using Finite Element Analysis for Rotary Ultrasonic Machine

Abstract

In this paper, a finite element analysis (FEA) has been used for the design of horn with different Bezier profiles for rotary ultrasonic machine (RUM). First, for validation, the results are compared with available literature. FEA-based MATLAB code is developed for finding the stress components, axial amplitude, and resonance frequency over the domain of horn with different Bezier profiles. In domain of horn with different Bezier profiles, the component of stresses is studied and found that the stress generated is within the endurance strength of the selected material. The amplification of the proposed horns is 24%, and 18% higher than the traditional linear Bezier horn with same length and diameters of surface end. For RUM, effect of inertia (self-weight or gravity of horn) on domain has been studied for horn with different Bezier profiles using FEA. The effect of tool shape and size on the stress distribution for horn have also been studied.