Enhanced Vibration Control of Ultrasonic Tooling Using Finite Element Analysis

Abstract

Abstract The use of finite element analysis (FEA) in high frequency (20–40 kHz), high power ultrasonics to date has been limited. Of paramount importance to the performance of ultrasonic tooling (horns) is the accurate identification of pertinent modeshapes and frequencies. Ideally, the ultrasonic horn will vibrate in a purely axial mode with a uniform amplitude of vibration. However, spurious resonances can couple with this fundamental resonance and alter the axial vibration. This effect becomes more pronounced for ultrasonic tools with larger cross-sections. The current study examines a 4.5″ × 6″ cross-section titanium horn which is designed to resonate axially at 20 kHz. Modeshapes and frequencies from 17–23 kHz are examined experimentally and using finite element analysis. The effect of design variables — slot length, slot width, and number of slots — on modeshapes and frequency spacing is shown. An optimum configuration based on the finite element results is prescribed. The computed results are compared with actual prototype data. Excellent correlation between analytical and experimental data is found.