Optimal Design and Experimental Verification of Ultrasonic Cutting Horn for Ceramic Composite Material

We developed and optimized a block-type ultrasonic horn that can be used for cutting hard materials. The proposed sonotrode consists of an aluminum tungsten carbide blade to increase the designed initial block has double slots exponential stepped profile. finite element model analyzed characteristics natural frequency displacement. formulated DOE table response surface perform sensitivity analysis analyze correlation between design variables horn. optimal was derived via multi-objective problem maximize amplitude uniformity separation. fabricated verified it experimentally. An experiment conducted find force with ceramic composite A test conventional machine under same condition also compare force. cutter requires 70% less than cut material application is much cleaner no crack delamination cutter.