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Ultrasonic Sonotrode for Welding System with FEA Analysis

This ultrasonic welding horn customized depeding on customer's requirements.

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  • Rps-H15
  • Rps-sonic
  • Rps-H15

Ultrasonic Sonotrode for Welding System with FEA Analysis


First. The amplitude parameter of the horn.

The amplitude is a key parameter for the material to be welded, which is equivalent to the temperature of ferrochrome. If the temperature is not reached, it will not be welded. If the temperature is too high, the raw material will burn or cause structural damage and strength will deteriorate. .

Because the transducers selected by each company are different, the amplitude of the transducer output is different. After adapting the different ratios of the horn and the horn, the working amplitude of the horn can be corrected to meet the requirements. The output amplitude of the energy device is 10-20μm, and the working amplitude is generally about 30μm. The variation ratio of the horn and the welding horn is related to the shape of the horn and the welding horn, the front and back area ratio and other factors. In terms of shape, such as exponential luffing, functional luffing, stepwise luffing, etc., the influence on the transformation ratio is large, and the front-to-back area ratio is proportional to the total transformation ratio. If your company chooses welding machines of different company brands, the easiest way is to make the amplitude parameters stable according to the proportion of the working welding horn.

 

Second. horn frequency parameters

Any company's ultrasonic welding machine has a center frequency, such as 15KHz, 20KHz, etc. The operating frequency of the welding machine is mainly determined by the mechanical resonance frequency of the transducer (Transducer), the horn (Booster) and the welding horn (horn). .

The frequency of the generator is adjusted according to the mechanical resonance frequency to achieve uniformity, so that the horn operates in a resonant state, and each part is designed as a one-half wavelength resonator. Both the generator and the mechanical resonance frequency have a resonant working range. For example, the general setting is 0.5KHz. In this range, the welding machine can basically work normally. When we make each welding horn, we will adjust the resonant frequency. It is required that the resonant frequency and design frequency error is less than 0.1KHZ. For example, for a 20KHz welding horn, the frequency of our welding horn will be controlled at 19.90-20.10KHz with an error of 5%. o.

 

Third. Vibration node

The horn and the horn are designed to be a half-wavelength resonator with an operating frequency. In the working state, the amplitude of the two end faces is the largest and the stress is the smallest, while the amplitude of the node corresponding to the middle position is zero and the stress is the largest. The position of the node is generally designed to be a fixed position, but the usual fixed position is designed to have a thickness greater than 3 mm, or the groove is fixed. Therefore, the fixed position does not necessarily have a zero amplitude, which causes a certain sound and a part of the sound. Energy loss, for sound, is usually isolated from other components by rubber rings, or shielded with sound insulation; energy loss is considered when designing amplitude parameters.Ultrasonic Sonotrode for Welding System with FEA Analysis will hepl check the vibration node too.

 

Forth. Processing precision

Ultrasonic welding horn, because it works under high frequency vibration, should try to maintain a symmetrical design to avoid the unbalanced stress and lateral vibration caused by the asymmetry of sound wave transmission. The longitudinal transmission of ultrasonic vibrations, for the entire resonant system), unbalanced vibrations can cause heat and breakage of the weld hair.

Ultrasonic welding is used in different industries, and the processing accuracy requirements are different. For particularly thin workpieces, such as lithium-ion battery pole pieces and tab welding, gold foil coating, etc., the processing accuracy is high, all our processing equipment uses CNC equipment (such as machining centers, etc.) In order to ensure that the precision of the processing meets the requirements.

 

Fifth. horn life

- The service life of the welding horn only depends on two aspects: first, material, second, process.

Material aspects:

Ultrasonic welding requires metal materials to be flexible (small mechanical loss during sonic transmission), so the most commonly used materials are aluminum alloys and titanium alloys.

The material is the main reason for ensuring the life of the ultrasonic horn and the effect of the welded product. The process of completing the horn is complicated, so it is not only the horn engineer design that must carefully select the material.

It is also necessary to know what kind of material is required for the product itself to avoid inadvertent influence on its timeliness and quality.


ultrasonic sonotrode

ultrasonic transducer horn

FAQ:

1. What’s the warranty of your transducer and equipment.

Our warranty is one year for both transducer and equipment, but we can supply you Components free even out of warranty.

 

2. What’s frequency transducer you supply?

We can supply transducer from 15Khz to 70Khz depending on your requirements or application.

 

3. What’s the using life of your transducer?

Under correct working environment, our transducer can work 5~10 years

 

4. What’s the using life of your generator?

Under correct working environment, our generator can work 8~10 years

 

5. Does your products exported before?

Yes, our transducer exported to USA,south America, EUROPE, Middle East, and Russia for many years.

 

6. Do you supply sample for test?

Yes, you can order on sample from our company first , we will return you the sample cost when you order in the future.

 

7. Do you supply OEM work?

Yes, welcome to ask for OEM cooperation , we have OEM produced for USA and German customer for many years, also hope to get more OEM order to enlarge our business.

 

8. how to customize transducer ?

For two ways for customize transducer, first way, you supply me sample , I will customize depending on your sample. Second, you give us all parameter and drawing , we can customize depending on your information.

 

9. Can you generator connect to PC, PLC or internet .

Yes, we have different version generator, it can connect to PC. PLC, even internet.Also the price different.

 

10. What we can get if the transducer/equipment broken during the warranty?

All our transducer and generator tested at least 48 hours before shipment , so we have confidence to our equipment. Of course, We will send you new transducer/ equipment if it broken in the warranty. At the same time, we need to find the problem , why it broken so fast.


The service life of the welding horn is determined by two aspects: 1. Material, 2. Process Material: Ultrasonic welding requires good flexibility of the metal material (the mechanical loss during the sound wave transmission process is small).

Good ultrasonic welding horn material is one of the main reasons to ensure the effect of ultrasonic mold life on the welding product. The process of mold completion is complicated. Therefore, it is not only the design of the mold engineer that the material must be carefully selected, but also the material that the product requires to be used to avoid inadvertent influence on its timeliness and quality.



   The characteristics of the various materials are now outlined as follows:

 First. Aluminum-magnesium alloy (7075-T651, 2024-T651, 6061-T651)


1, 7075T651: used in vibration system and Horn manufacturing, the material has extremely high mechanical yield strength, high hardness, ultrasonic welding horn, strong thermal conductivity, is an ideal ultrasonic mold manufacturing material;


2, 2024T651: generally used and manufactured by HORN, good enthalpy, strong thermal conductivity, moderate hardness, used for general plastic products.


3, 6061T651: used in the production of HORN with lower output, good 轫, soft quality.


Second. Titanium alloy: 

It is used for continuous vibration, with high enthalpy, good heat conduction, high hardness and high cost.



Third.  hard aluminum alloy:

 Chinese material, used for ordinary aluminum processing, low heat conduction, high mechanical loss to ultrasonic, low cost.

 



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 Ms. Yvonne
  sales@xingultrasonic.com   
 0086-15658151051
   Room 1103B, Nature business building ,  NO.1160 GongWang Road ,FuYang, Hangzhou,Zhejiang,China

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