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Ultrasonic Plastic Welding Horn Design Worth Reading Right Now

The ultrasonic welding horn is an indispensable and important part of ultrasonic welding equipment. Its function is to transmit the vibration energy generated by the transducer into the workpiece to be welded, and the ultrasonic horn must work in a resonant state, in other words, its inherent resonant frequency must match that of the transducer, as well as its amplitude, and the shape of the welding horn must be adapted to the shape of the workpiece to be welded.

ultrasonic welding horn design FEM analysis1

Ultrasonic plastic welding machine horn design will directly determine the welding effect of the workpiece. Many poor designs, and with no fine workmanship welding horns, will often cause short life, easy to damage, the workpiece welding is not beautiful, not solid, and can not meet the airtight, watertight requirements, etc., so how to make a good ultrasonic welding machine horn?

For the production of an ultrasonic welding horn, the following points must first be confirmed.

  1. Choice of material (which determines the service life of the horn, and the degree of wear resistance)
  2. Shape and structure (fit the workpiece to be welded, while affecting the amplitude gain of the horn).
  3. Frequency and tolerance range.

Choice Of Material

Most horns are made from three materials: titanium, aluminum, and steel.

Aluminum alloy: this is one of the most commonly used materials, with good mechanical properties (hardness and ultrasonic propagation speed) and reasonable prices, is the preferred material for ultrasonic molds.

Titanium alloy: with excellent acoustic properties, can withstand maximum mechanical stress three times that of aluminum alloy, has relatively excellent wear resistance, but is relatively expensive. Also commonly used for welding plastics containing glass fibers.

Alloy steel: used for welding plastic parts where aluminum and titanium alloys cannot be applied, has high hardness and maximum wear resistance, and is generally hardened before use.

titanium, aluminum, and steel horn
shape and structure of the horn

Shape and Structure Of The Horn

Usually, the ultrasonic welding machine horn is generally divided into 2 pieces (upper and lower die), upper die is linked to the transducer, the lower die is fixed in the ultrasonic welding machine work base, upper die is used to transmit ultrasonic energy, so the frequency must be consistent with the frequency of the ultrasonic generator, otherwise, there will be damage to the horn, the lower die is mainly used to fix the plastic workpiece, which can play the effect of the fixed workpiece, can be designed and made by yourselves.

Frequency And Tolerance Range

The frequency of the horn is calculated by the ultrasonic manufacturer according to the material, size, and shape of the workpiece through professional software analysis, the tolerance is usually about ±0.25% of the rated frequency, and each horn’s frequency must be tested, and matched to the ultrasonic system.

FEA Analysis of the ultrasonic horn

Even with many years of experience, we are convinced that the best ultrasonic welding horn can only be produced through rigorous testing and quality control. Combining the acoustic and mechanical characteristics of the welding horn, we provide the product that best meets the needs of our customers.

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