Design And Finite Element Analysis Of Ultrasonic Amplitude Transformer Horn

Along with the finite element technology development and improvement, more and more projects are solved by this method. The ultrasonic machining is one of the most important machining crafts in the modern advanced mechanical manufacturing industry, which has great significance to the development of the new cutting technology.This article takes the acoustic horns as the object, selects 20 KHz as the ultrasonic frequency, and selected the 45 steel as the acoustic horns' material, the ratio of the diameters of the beginning and ending is 4, the diameter of the big-end is 56 mm. We used large-scale finite elements method ANSYS and function formidable mathematics software MATLAB as the tools. Author have carried the exponential type acoustic horns, hyperbola type acoustic horns, the stepped acoustic horns and the cone acoustic horns on the simulation analysis and simulation emulation. First, calculated and analyzed the mathematic models of exponential type acoustic horns, hyperbola type acoustic horns, the stepped acoustic horns and the cone acoustic horns on the simulation analysis and simulation emulation by MATLAB. Then the frequency equations, the resonant lengths, the displacement pitch point, the amplification coefficients and the input resistance were obtained. separately, and then obtained external dimensions and other parameters of the acoustic horns. And extracted theory displacement distribution maps and the theory stress envelopes of each acoustic horn, according to the charts, we know the biggest displacement occurred at the small end of each acoustic horn, and discovered the biggest stress spots. In the base of that, entities of the three-dimensional model had been created by the bottom-up method in ANSYS. First, defined the key points, and then created lines, areas and volumes. After that expansionary calculation were carried on. Examined 1～10 steps modal natural frequency, observed and analyzed results from the nephograms. Dynamic performance analysis to the acoustic horns carried on under the resonance condition. Then calculated the oscillation amplitudes of the free end surface, and then obtained the natural frequency, displacement nodes, amplitude magnification coefficient and stress enormous of the acoustic horns. Through comparison to the calculate results of the ANSYS and MATLAB, the theory results calculated by MATLAB is closed to the simulate analysis and harmonious response analysis results which calculated in ANSYS. At the same times, indicate that using finite element method to simulate dynamic analogies can overcomes the problems to a great extent that the mathematical model is hard to describe and computation is difficult. At the same time, it supplies an inexpensive, quick and effective method for getting rid of the traditional examination which is both time-taking and laborious. The results indicate that the application finite element method can obtains high precision and the article has reference value to the design and research of the singleness acoustic horns and the combination acoustic horns.