Design and performance analysis of Multi-linear Horn for Ultrasonic machining application using FEM approach

Abstract

This work reports an ultrasonic horn design and development for improving the performance of ultrasonic machining process in terms of better material removal rate for the same input conditions. The suitable operating frequency range (20 kHz-25 kHz) of the horn is analyzed with the help of finite element approach using the Ansys and for modelling Creo software is used. Typically, the machining tool vibrates around 10-20 μm, but for effective machining requires the more magnitude or intensity (80-200 μm) of vibration within this frequency range. Performance of ultrasonic horn mainly depends on the geometrical aspects and type of material used. In this work, we focus on the ultrasonic horn with an innovative design compared to earlier reported works to obtain the maximum magnification factor within permissible stress limits. The standard criteria “stresses below the permissible limit and mode shapes at different resonance frequencies (modal analysis)” are considered while designing the horn for avoiding the tool and horn failures during machining. The optimum numbers of elements are identified to mitigate computational time based on the optimum mesh criteria. In this study, we have analysed the equivalent stresses, magnification factor (ratio of output to input amplitude) of the horn by harmonic response analysis, which can be used to arrive at the effective machining processes. Finally, the magnification factor is increased within the safe stress limit using our innovative horn design. Newly, designed horn’s performance is compared and validated with the earlier reported literature at a similar input parameters or loading conditions.