Optimization of CCC and CEC Horns by Response Surface Method and Modal Analysis

An ultrasonic system consisting of a generator, a transducer, and a concentrator has been used recently in various production methods to reduce the friction force during the process. The ultrasonic horn (concentrator) is one of the important tools for focusing and transmitting the ultrasonic vibrations to a target area. In this research, the effects of horn input parameters (i.e. diameter of the connecting area to the transducer, length of the bottom part, length of the middle part, length of the upper part, and diameter of the transmission part) in two types of horns (Cylindrical-Conical-Cylindrical and Cylindrical-Exponential-Cylindrical) on the output parameters such as the maximum resonant frequency of longitudinal mode was investigated. The design of experiments was carried out by the response surface method in the Minitab software. The simulation of the process was done using the modal analysis in the Abaqus Explicit software. The optimal dimensional values in both CCC and CEC horns to reach the maximum resonant frequency in the longitudinal mode were obtained. Finally, these two horns were manufactured using optimal values. The experimental and numerical results of the vibrating horns showed an error of less than ۱%, which confirmed a good and acceptable optimization