• Journal of the Korea Convergence Society
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• v.11 no.1
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• pp.175-180
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• 2020

In this study, we developed a micropattern technology in the shape of RFID TAG antenna using ultrasonic micropattern manufacturing system developed to enable micropattern technology. The ultrasonic tool horn in longitudinal vibration mode was installed in the micropattern manufacturing system to develop the ultrasonic press technology for the micropattern antenna shape of the RFID TAG antenna shape on the insulating sheet surface. The ultrasonic shaping technology was manufactured by applying the resonance design technique to a 60kHz tool horn, and by using the micropattern manufacturing system, the coil wire having a thickness of 25㎛ can be ultrasonically press-molded on an insulating sheet of 200㎛ or less. In ultrasonic press technology, the antenna shape having a minimum line width of 150㎛ could be molded without disconnection, peeling, or twisting of the coil wire.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1991.04a
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• pp.39-45
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• 1991

최근 진동 절삭 가공 및 용착 등에 초음파 진동을 동력적으로 응용하려는 시도가 급증하고 있다. 이 분야에서는 진동자에서 발생되는 미소한 진폭의 적은 초음파 에너지를 큰 에너지로변환시키는 방법으로서 진동자의 끝단에 진동자와 동일한 진동수의 고유진동수를 가진 부스터와 tool horn을 부착하여 공진에 의해 진폭의 증폭으로 큰 에너지를 얻고 있다. 그러나 부스터와 tool horndml의 고유 진동수가 진동자의 진동수와 일치하지 않을 경우에는 tool horn 의 끝단에 진동이 전달되지 않는 결과를 초래하게 된다. 본 연구에서는 유한 요소법을 이용하여 축대칭 및 3차원 형상의 tool horn에 대한 고유 진동수 계산 퍼스널 컴퓨터만으로도 tool horn을 설계할 수 있도록 하여 이 결과를 실용 tool horn 설계 제작에 손쉽게 이용할 수 있도록 하였다.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.12 no.5
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• pp.135-140
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• 2013

Ultrasonic cutting is a kind of eco-technique and cost-effective technique to be used for cutting of various materials such as baked product, fresh/frozen food, rubber, textile, wood, bone, etc. The performance of ultrasonic cutting is affected by design of cutting horn and cutting conditions. Specially the design of horn to resonate at the longitudinal direction is most important. To analyze the problems from which cracking and noise are often generated with conventional cutting horn, FEA is carried out, and then improved cutting horn which can reduce maximum stress and stress concentration is designed. Vibration characteristics, resonant frequency, gain, and amplitude uniformity of the cutting horn designed optimally are evaluated through FFT analysis and compared with those of conventional cutting horn.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.21 no.1
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• pp.70-75
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• 2012

The technique with ultrasonic vibration refers to the many industries. Especially Ultrasonic Connection Method is widely used for mobile battery, secondary battery, automobile components and also they recently started using it for terminal connecting of solar community battery. In this study, ultrasonic welding horn is analysed and designed with FEM, then manufactured based on it. Resonance frequency and amplitude of horn would be measured and compared with the designing result to judge the suitability. Al/Al specimen is welded by the manufactured horn and verify its performance via the weldability evaluation.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.11 no.1
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• pp.76-81
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• 2012

Ultrasonic metal welding is one of the welding methods which welds metal by applying high frequency vibrational energy into specific area at constant pressure, avaliable in room temperature and low temperature. Ultrasonic metal welder is consisted of power supply, transducer, booster, and horn. Precise designing is required since each parts' shape, length and mass can affect driving frequency and vibration mode. This paper focused to horn design, its length L was set to 62mm by calculating vibration equation. By performing modal analysis with various shape variable b times integer, when length of b is 30mm the output was 39,599Hz at 10th mode. Also by performing harmonic response analysis, the frequency response result was 39,533Hz, which was similar to modal analysis result. In order to observe the designed horn's performance, about 4,000 voltage data was obtained from a light sensor and was analyzed by FFT analysis using Origin Tool. The result RMS amplitude was approximately 8.5${\mu}m$ at 40,000Hz, and maximum amplitude was 12.3${\mu}m$. Therefore, it was verified that the ultrasonic metal welding horn was optimally designed.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.12 no.2
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• pp.55-61
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• 2013

The horn is a key part of the ultrasonic welder. As the shape, mass and material of a horn have effects on the resonant frequency and the vibration mode in ultrasonic welding, a horn has to be designed and manufactured accurately. In this study, 40kHz band horn was designed and manufactured through the vibration mode and finite element analysis. A result of modal analysis showed that the natural frequency of the horn was 39,794Hz, and the frequency response by a harmonic response analysis was 39,800Hz - close to the intended frequency, 40kHz. In addition, weldability of the developed horn was estimated by welding of two Ni sheets and tensile-shear test of welded samples. It was shown the developed horn could be used in metal sheet welding.

• Korean Journal of Metals and Materials
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• v.49 no.8
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• pp.642-648
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• 2011

This paper describes an experimental study on ultrasonic welding of similar and dissimilar metals. There are optimum welding conditions which are found for welding of Al/Al and Al/Cu. It evaluated weldability using tensile test, SEM observation and EDX-ray analysis. Both ultrasonic welding of Al/Al and Al/Cu have amplitude as the variable factor. Al/Cu welding was examined again with welding time as variable factor to find the best conditions. The more welding time or amplitude increase, the better weldability. The optimum conditions for ultrasonic welding of Al/Al were formed at pressure 0.25 MPa, welding time 0.25 sec, amplitude 90%. Pressure 0.25 MPa, welding time 0.4 sec, amplitude 80% are optimized for Al/Cu ultrasonic metal welding and solid-state diffusion generated by ultrasonic vibration and frictional heat is confirmed at the welded interface.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.26 no.4
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• pp.425-429
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• 2017

During ultrasonic welding, plastic deformation, elastic hysteresis, and friction generate heat at the contact portions of the two materials to be welded, theoretically analyzing and experimentally measuring the temperature at the welded part are very important for identifying the heat affected zone. However, the welding temperature during ultrasonic welding wherein welding is performed in less than a second is a challenge. We investigated the effects of welding conditions such as welding time, welding pressure, and the ultrasonic vibration amplitude of horns on the temperature of welded surface of a Ni sheet of thickness 0.1 mm. We used a horn with a resonance frequency of 40 kHz and an ultrasonic welder. The temperature was measured using a intrared sensor, and its characteristics were investigated. Experimental results showed that increase in welding time and pressure and ultrasonic vibration amplitude of horns generally caused the increase in surface temperature of the weld.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.25 no.2
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• pp.105-111
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• 2016

Ultrasonic metal welding, unlike the conventional welding techniques, does not require an external heat source, welding rod, or filler metal. Therefore, ultrasonic metal welding is not only economical but also environment-friendly, and hence, it has been receiving much attention. In ultrasonic welding, heat is generated because of the plastic deformation and the friction between both surfaces of the welded materials. It is important to identify the heat-affected zone by measuring the temperature generated at the weld. In this study, the effects of the welding pressure, welding time, and vibration amplitude on the temperature distribution in the weld were evaluated by performing a transient thermal analysis of the heat generated during ultrasonic metal welding. The experimental results indicated that the temperature of the weld tends to increase with the welding time and vibration amplitude. However, an increase in the pressure does not affect the temperature of the weld largely.

• Journal of the Korean Society for Precision Engineering
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• v.23 no.8 s.185
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• pp.195-202
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• 2006

High-speed machining (HSM) with excellent quality and dimensional accuracy has been widely used to create 3D structures of metal and plastics. However, the high-speed machining process is not suitable for the rapid realization of 3D thin-walled product because it consumes considerably long time in fixturing process of a work piece. In this paper, an effective rapid manufacturing process is proposed to fabricate 3D thin-walled products directly using HSM, phase change filling and ultrasonic welding. The filling process is useful to hold the thin-walled product during the machining step. The ultrasonic welding process is introduced to make one piece product from two piece parts that are machined by HSM and filling process. The proposed rapid manufacturing (RM) process has been shown that the RM process enables to fabricate the 3D thin-walled products using ABS plastics and aluminum metals from 3D CAD data to functional parts.