Study on a Large-Scale Three-Dimensional Ultrasonic Plastic Welding Vibration System Based on a Quasi-Periodic Phononic Crystal Structure

Abstract

The uniformity of amplitude distribution and amplitude gain are two main factors affecting the performance of ultrasonic welding vibration system. In order to improve the uniformity of amplitude distribution and amplitude gain of welding surface to enhance the performance of the vibration system, a new design method of a large-scale three-dimensional ultrasonic plastic welding vibration system based on a quasi-periodic phononic crystal structure is proposed. In this method, the composite horn combined with a conical section and a cylindrical section can effectively improve the output amplitude gain of the welding surface. In addition, the method forms a quasi-periodic phononic crystal structure by slotting in a large-scale three-dimensional tool head, and utilizes the band gap property of the structure to effectively suppress lateral vibration of the tool head and improve the amplitude distribution uniformity of the tool head’s welding surface. However, when the size of the tool head is relatively large, the quasi-periodic phononic crystal structure cannot suppress the lateral vibration very well. Therefore, the paper processes fan-shaped slopes on the output surface of the tool head which can further improve the uniformity of the amplitude distribution and amplitude gain. Finally, the simulation analysis and experiments show that the design method can optimize the large-scale three-dimensional ultrasonic plastic welding system, improve the uniformity of the vibration distribution and increase the output amplitude gain of the welding surface.

Numerical Evaluation of State of the Art Horn Designs for Rotary Ultrasonic Vibration Assisted Machining of Nomex Honeycomb Composite

“…However, the amplitude of vibration greatly reduces at the tool end. Researchers have investigated the performance of both cylindrical-conical (conical portion at the tool side) and conical-cylindrical horn designs (conical portion at the transducer side), however cylindrical conical arrangement has been used in commercially available ultrasonic systems [31,52,53].…”

“…1) [4,5] consists of ultrasonic generator, piezoelectric transducer, mechanical horn and cutting tool. The ultrasonic generator converts low frequency (50)(51)(52)(53)(54)(55)(56)(57)(58)(59)(60) signal to high frequency (more than 20…”

“…The lengths and diameters of the cylindrical portions, cross sectional shape (circular to rectangular) [41] and the location of mountings has also been varied to optimize and improve the performance of ultrasonic horn [42][43][44]. Hybrid horns, which are combination of basic horn profiles such as multi-step [45,46], cylindrical-conical / step-conical [31,36,39,43,44,[47][48][49][50][51][52], double conical [6,53], step-exponential / cylindrical-exponential [43,44,[53][54][55], multistep conical [56,57], step-catenoidal [54], step-Gaussian / cylindrical -Gaussian [58] and cylindrical-conical-exponential [59] have also been designed and analyze to assess horn performance. Other horn designs have also been attempted in order to improve the amplitude of vibration while keeping the stresses in acceptable limits [33,[60][61][62][63][64].…”

Parametric Study of Bolt Clamping Effect on Resonance Characteristics of Langevin Transducers with Lumped Circuit Models

“…There are a variety of booster shapes, including stepped horn, conical horn, Gaussian-curved horn, and so on. We use an exponentially shaped horn here because it allows structural stability, a proper amplification ratio, and design simplicity through lumped circuit models [19]. The decaying rate at which the horn's cross-sectional area decreases is 34.7 m −1 in the axial direction.…”

Effect of Cavity Structure on Acoustic Characteristics of Phononic Crystals Based on Double-Layer Plates

“…Research on phononic crystals has mainly focused on the effects of various materials and structures on the band gap of two-dimensional phononic crystals [15][16][17][18][19][20]; however, no structure with infinite z-axis size exists in the real world. Research on three-dimensional phononic crystals has gradually advanced to research on three-dimensional phononic crystals plate [3,[21][22][23]. Many studies have examined the band gap of phononic crystals plate.…”