Node flange optimization and parametric design of a circular arc transition stepped ultrasonic horn
                             LU Song1,2, ZHOU Chengquan2, FENG Guangzhi2,LIU Jiajun3 , LI Mingyu1, LIU Zhengfeng2
(1.Shenzhen Graduate School, Harbin Institute of Technology, Shenzhen 518118, China;2.Hans Laser Technology Industry Co., Ltd. ,Shenzhen 518103, China; 3.College of Mechanical Science and Engineering, Jilin University, Changchun 130012, China)

Abstract: Aiming at the problems that the flange of longitudinal vibrating horn for ultrasonic plastic welding was needed to be easyclamping and with no vibration, the rigidity and machining quality of the thin plate flange was not easily guaranteed, and the frequency of horn was easily shift with a thick plate flange, a circular arc transition step transformer was preliminarily designed and added a thin plate flange to the node location. Then a block was added on the outside of the thin flange with ANSYS Workbench Shape Optimization tool for optimization to guarantee the flange strength with less weight added. Then the parametric design of the horn was made for fixing horn length to make the resonance frequency around 19.75 kHz~20.15 kHz and to locate the node in the flange with the twocylinders' length as design variables. The results indicates that the vibration profile of the optimized horn is axial stepped distribution, and there is no vibration in the flange and it could be easily clamped at the flange .The mass of the thin flanged horn is 0.85 kg. The optimized horn is 0.914 kg, the mass is increased by 7.5%, the equivalent stress is reduced by 21.4%,the maximum principal stress is reduced by 59.6%.

Key words: ultrasonic horn; node flange optimization; ANSYS DesignXplorer; ANSYS Shape Optimization