• Journal of the Korea Academia-Industrial cooperation Society
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• v.11 no.12
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• pp.4735-4741
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• 2010

The ultrasonic metal welding is highly used in extensive field due to the possibility for welding of various materials such as new materials, plated structures and etc, and its welding conditions has been diversify. In this paper, one-wavelength tool horn of step type designed for ultrasonic metal welding of dissimilar metal sheets has performed by FEM analysis. FEM analysis is applied to predict the natural frequency of ultrasonic tool horn and use of in the optimal design of ultrasonic horn shape. And the optimal design of one-wavelength step horn is confirmed experimentally using natural frequency analysis system.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.20 no.12
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• pp.94-101
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• 2019

In this study, the FEM technique was applied to design the shape of the horn that transmits ultrasonic vibration energy to the base material, and the shape of the welding horn with a one-wavelength bar shape used in the 20kHz region was designed. The shape design of the horn was performed by applying the rod longitudinal vibration theory to Ansys APDL (Ansys Parametric Design Language). Twenty-five models were designed using the ratio of the area of the input and output surfaces of the vibration and the length of the horn to derive the appropriate horn shape. The horn was designed with a total length of 130mm, a step length of 65mm, and an output area of 28.79mm. The horn was fabricated using the optimized dimensions, and the vibration and displacement characteristics of the horn were evaluated using the measurement system. Finally, a uniform longitudinal step horn was designed, and more than 97.4% of the uniformity of the tip was secured. The amplitude ratio of the optimized horn was improved by 51%.