Modal Analysis of Ultrasonic Horn using Finite Element Method

Abstract

Abstract Ultrasonic Machining (USM) is a preferred advanced machining method for hard and brittle material. This process can be conveniently combined with other machining processes to develop different hybrid machining processes. The machining capability of the USM process largely depends on the amplification of the amplitude of vibration produced by transducer. The ultrasonic horns vibrate in longitudinal direction and transfer the vibrational energy from transducer to workpiece. The design of ultrasonic horn is utmost important because incorrect design not only deteriorate the machining performance but also the cause damage to the vibration system and generator. In this study, modal analysis of two different horn profiles which are comparatively difficult to manufacture i.e. steeped and exponential have been performed using finite element based ANSYS software. Mode shape and natural frequencies of the above two profiles made of Titanium and Aluminium have been taken into consideration. From the result it is observed that for stepped profile Titanium horn produces higher natural frequency for all the six modes but in case of exponential profile Aluminium horn produce more frequency than Titanium alloy.