23 Vibration Analysis of Ultrasonic Metal Welding Horn for Optimal Design

Ultrasonic energy is used in plastics welding, metal welding, drilling and lots of processing fields. Because of the recent miniaturization and light weighting of electronic parts and mechanic parts, these days we need a better welding method, which is the Ultrasonic metal welding. Which is a more accurate, more minimized welding method than before. Ultrasonic metal welding machine consist of a Power Supply that changes a 50 ∼ 60Hz electrical power to a 20,000hz ∼ 40,000hz electrical energy, a Transducer that changes electric energy to mechanical vibration energy, a Booster that reduce or amplifies the amplitude of the Transducer, a Horn that welds workpieces by transmitting vibration energy. The Transducer, Booster, Horn has to be designed and made very accurately because the shape, length, mass and etc effects the resonant frequencies and vibration mode. In this research, to design the Transducer and the Horn, we decided the size by the vibration equation, calculated and analyzed the natural frequency by the modal analysis and harmonic analysis. Using Ansys that is analysis program.