Abstract
Ultrasonic welding is faster, environmental friendly, and more efficient than conventional welding. Ultrasonic welding stack, the key part in ultrasonic welding equipment, is composed of transducer, booster, and horn. In the case of ultrasonic welding, wear in the welding tips or breakage of horn occurs because ultrasonic vibration of tips is transmitted directly to the welding material. If grinding of the tips is repeated several times, the mass of horn is reduced and the frequency characteristic is changed. So, there is a limit to refurbishment. In additions, as materials of horn are relatively expensive, some cost problems could be occurred for replacing horns. This study, in order to reduce the manufacturing cost of horn, devised a tip-replaceable ultrasonic horn so that its tip can be easily replaced whenever it is worn. For the designed shape, natural frequency and vibration mode are analyzed using FEA. Through the FEA, the optimal tip-replaceable horn with resonance frequency of 40 kHz is proposed.
Highlights
Ultrasonic welding is a faster, more environmentally friendly and simpler, more efficient welding method than conventional welding
The tips knurled in the horn main body require direct contact with the welding material and transmit ultrasound vibrations, which causes tip wear during welding
Pins are assumed to be assembled without any counterbores on the drilled holes, because there are no significant differences in the natural frequency and mode shape
Summary
Ultrasonic welding is a faster, more environmentally friendly and simpler, more efficient welding method than conventional welding. The tips knurled in the horn main body require direct contact with the welding material and transmit ultrasound vibrations, which causes tip wear during welding. In this case, re-grinding decreases the mass of the horn and changes the frequency characteristics. USA, applied for a patent for an ultrasonic welding horn that can replace a tip using a collet. Most of these patents relate to half-wave length horns. We designed a tip-replaceable ultrasonic welding horn with resonance frequency of 40 kHz and analyzed vibration characteristics using FEA (finite element analysis)
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