An analytical approach to design horns and boosters of ultrasonic welding machines

Abstract This paper presents a new design approach for two main components of an ultrasonic plastic welding machine, booster and horn, based on analytical model. The procedure is developed due to the lack comprehensive precise model rapid analysis these components. previous models use one-dimensional wave equation that causes significant errors in designing with large lateral dimensions. Three-dimensional vibrations are considered developing using apparent elasticity method. In this way, longitudinal frequency equations coupled radial by mechanical coupling coefficients. Also, damping materials taken into account. can be adapted calculate resonant length or frequency. To verify model, results compared numerical simulation. difference between resonance less than 0.02%. Moreover, experimental modal performed, which shows 0.9% error results. Article highlights A boosters horns has been accuracy calculating frequencies more