Why is the weld horn mold hot and cracked?

What is an ultrasonic welding horn?

Ultrasonic welding horn is a generic term for all ultrasonic transmitting ends and is an indispensable part of ultrasonic welding equipment. Its function is to couple the ultrasonic waves generated by the transducer into the object to be processed. Because it transmits ultrasonic waves, the welding horn must work in a resonant state, that is, its natural resonant frequency should match the transducer. Secondly, The amplitude should be uniform and the shape of the end face of the weld horn should be adapted to the shape of the workpiece being welded.

What is the reason why ultrasonic waves are easy to crack?

1. Unreasonable design leads to poor resonance of the mold, and the sound wave is retained in the mold itself and consumes a certain amount of energy. Mold performance; no-load power is large, the sound wave is trembling, the connecting end face and the mold are hot, and the connecting screw is broken.

2, the processing technology is simple, the production process is not standardized - resulting in large mold stress changes caused by the mold no-load loss power and hot.

3, the mold material is unqualified - resulting in no-load loss power is unstable and large, the mold is hot.

Ultrasonic mold production process:

1. Ultrasonic mold design: The structure and material of the mold and finite element analysis are designed according to the product structure, material and welding requirements of the products to be welded.

2, ultrasonic mold materials, design has determined the material model and specifications, here is mainly selected material suppliers (qualified manufacturers) to determine the material quality.

3, the production process, the different internal pressure of the mold produced by the different production processes are different, the size of the mold (no-load power) is different.

4, mold testing and test welding, first of all to determine the frequency of use of the mold meets the requirements, the machine test mode to determine its mold power consumption is the smallest (or within the allowable range).

After the mold meets the above conditions, the product is tested and welded. Debug welding parameters. Until the welding is satisfactory (perfect).

Selection recommendations:

1, 6061-T651 aluminum alloy material mold production cost is the lowest, followed by 2024-T351, 7075-T651.

2, titanium alloy materials, expensive materials, difficult to process; but the strength and toughness of the mold is the best. The molds made are more durable.

3, alloy steel mold, material prices are cheap and expensive, toughness and good steel materials are more expensive! After processing and heat treatment is also essential. Mainly solve the ultrasonic mold hardness (wear resistance), mostly used in ultrasonic metal welding.

We know that when an object vibrates, it makes a sound. The number of vibrations per second is determined by the frequency of the sine wave. The larger the amplitude of the waveform, the lower the frequency and the greater the vibration of the mechanical vibration wave. The energy of an object's vibration is proportional to the vibration frequency. The larger the amplitude, the faster the output energy.