Design of Bezier profile horns by using optimization for high amplification

Abstract

Rotary ultrasonic machine (RUSM) has a lot of applications in industries, with the recent uses of stronger and harder materials. Machining performance of RUSM depends on the design of the horn. A horn also known as a tool holder or concentrator is a waveguide focusing device, which has a decreasing area of the cross section from the upper to lower end. In RUSM, the high amplification factor of the horn is required to increase tooltip vibration for getting a high material removal rate. In this study, the design of the horn using an optimization procedure and finite element analysis (FEA) has been done. FEA-based MATLAB code has been developed for finding all the stress components, axial amplitude, and resonance frequency. Results are validated from the experimental data available in the literature, and it has been found that it is in good agreement with the literature. The amplifications of the horns with cubic and quadratic profiles 23.8% and 19%, respectively, are higher than the traditional horn with the same length and diameters of the ends. Stresses at different locations have been found within the allowable endurance limit. The effect of frequency on the stress distribution has also been studied and found that the variation of stresses over the domain of horn increases with an increase in frequency, but the value of stress is much lower at the resonance frequency.