Design and performance analysis of ultrasonic horn with a longitudinally changing rectangular cross section for USM using finite element analysis

Abstract

Ultrasonic machining is one of the non-conventional techniques which is extensively used in industries for machining hard and brittle materials. The ultrasonic machine consists of different elements, namely ultrasonic transducer, ultrasonic horn and tool, out of which the performance of horn decides the ability of the ultrasonic machining in cutting the workpiece. The function of the horn is to amplify the amplitude of vibration from transducer end to the tool end. In this paper, an ultrasonic horn with a longitudinally changing rectangular cross section is designed using finite element analysis to match the required performance of a conventional ultrasonic machine. Subsequently, the feasibility of the design is checked by performing modal and harmonic analysis. In addition, an approximation mathematical model is developed for determination of magnification factor and the equivalent stress of the ultrasonic horn. Finally, the new design profile of ultrasonic horn is validated by comparing with the existing design of ultrasonic horns. The study indicates the dominance of suggested design over other designs, while maintaining the stress value well below the limit of endurance for the horn material.