Papers by Keyword: Horn Design

Abstract: Solar panels conduct electricity through aluminum strips on substrate surfaces. Ultrasonic roll welding can weld the conductive aluminum strips onto the glass substrates. This paper illustrates vibration characteristics and optimal design of amplitude horns used in the ultrasonic welding roll. Based on theoretical equations, this study used the ANSYS software to establish the parametric model according to design requirements. With the parametric model as the initial design, this study conducted modal analysis and harmonic analysis to obtain the vertical mode and disc bending mode of the horn, and measured the resonant frequency, amplitude amplification rate and stress distribution. Finally, this study implemented and verified the optimal coupled disc tool of the ultrasonic horn.

Abstract: Damaging temperature effects observed during ultrasonic cutting operations are typically a result of friction between the vibrating blade and material, and combustion of debris. In order to prevent the high temperatures causing damage, the ultrasonic blade has to cut with a sufficient speed. This can be achieved either by applying a relatively high static load or by increasing the working vibration amplitude of the cutting edge, however, the result can be poor operational control and exceeding the fatigue limit of the blade, respectively. In this paper, the effect of blade tip profile is considered, particularly with reference to the influence of the cutting edge contact area on temperature under different static loading conditions. Titanium blades, with different cutting edge profiles are tested in a series of experiments that monitor cutting speed, static load, temperature around the cut site, and vibration amplitude at the cutting edge. The blades are tested cutting bovine femur and artificial bone material, and the cut surfaces are examined for signs of damage after each test. The experimental data reveal that blades with a small cutting edge contact area cut at a lower temperature, and that signs of thermal damage are less evident.

Abstract: The design of high power ultrasonic cutting devices is based on tuning a blade to a longitudinal mode of vibration at a low ultrasonic frequency, usually in the range 20-100 kHz. To achieve the required cutting amplitude, gain is designed into the blade via profiling. It is expected that the use of higher-gain blades could enable longitudinal-mode guillotine-type cutting of a range of materials traditionally difficult to cut using this technology. Using a conventional high-gain blade, a feasibility study of ultrasonic cutting of bone is conducted using compact tension specimens of bovine femur. Finite element (FE) models are created, based on the assumption that the ultrasonic blade causes a crack to propagate in a controlled mode 1 opening. The models are compared with the experimental data collected from ultrasonic bone cutting experiments. Although the proposed cutting mechanism is supported by the data, the blade gain is insufficient to enable through cutting of long bone or other difficult to cut materials. Consequently, the paper examines the relationship between gain, profile, stress and nodal position for a range of ultrasonic cutting blades with increased gain.