Ultrasonic Titanium Rotary horn 35 kHz

An ultrasonic rotary horn intended to be excited at a frequency of from about 18 to about 60 kHz, which horn is a shaped, solid object having a rotational axis and a radial surface terminated by a first end and a second end.

The horn is racially symmetrical. The thickness of the horn at the rotational axis is greater than the width of the horn at the radial surface. The diameter, width, and thickness of the horn are selected for a desired frequency so that the horn, upon being excited by ultrasonic energy at such frequency which is input at the rotational axis at, and substantially perpendicular to, one or both ends, is adapted to resonate in a manner such that:

• The excited end moves substantially in phase with the movement of the source of excitation.
• The opposing end, whether or not it is actively excited, moves substantially out of phase with the movement of the excited end.
• The radial work-contacting surface also moves substantially out of phase with the movement of the excited end.
• In addition, the first end and the second end have a substantially convex configuration which comprises a central, circular, flat portion which is concentric with the rotational axis and a generally concave portion from the flat portion to said radial
• The horn exhibits a single nodal point at its geometric center.
• Working ultrasonic rotating horns / sonotrode frequency: 20 kHz, 23 kHz, 25 kHz (sound of silence), 30 kHz, 35 kHz, 36 kHz, and 40 kHz.
• Can be anodized or as here wolfram carbide coated for even more ware

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This ultrasonic composite horn / sonotrode is designed in 35 kHz,  but the huge advantage of little sound to be heard in welding

The ultrasonic composite horn / sonotrode is actually a half-wave coupled horns / sonotrode with two or more half-wave, tuned horns attached to it. This technology was first used in 1973. Because designs can often eliminate the need to invest in additional ultrasonic systems, they reduce equipment investment costs and minimize production time.

Composite ultrasonic horn / sonotrode designs are common on applications that cover a large surface area and on applications where there are multiple insertion, staking, or welding points. Some of automotive customers use composite ultrasonic sonotrodes / horns to attach insulator pads to door panels or similar,

Another common application that benefits from composite ultrasonic tooling is packaging (a vacuum-formed blister package). The ultrasonic composite horn / sonotrode saves manufacturers production time and costs, as it welds the package simultaneously at several different points, instead of using a multiple-head system or having an operator / machine ultrasonic weld each point separately.

Composite ultrasonic horns / sonotrodes are also  in applications where it’s difficult to create enough amplitude to weld. The amplitude at the face of a composite horn is higher than what could ever be achieved by a single large horn. The amplitude is designed into each of the individual half-wave horn attachments, not the coupler, a higher amplitude is generated at the weld area; this avoids causing excessive stress to the coupler horn.

Although composite horns / sonotrodes can eliminate the need for additional assembly systems, cut production times, and lower labor costs, they are more expensive than standard horns / sonotrodes. The added cost is due to the extra titanium or aluminum and machining time the composite horns require.

Typical ultrasonic composite horns / sonotrodes have aluminum couplers and titanium half-wave attachments. In addition to the expense of titanium, all of the half-wave attachments must be tuned within 50 cycles of each other. And they must be properly mounted onto the coupler horn. This design we have here is done with only Titanium, do to high amplitude.

The most common mounting method utilizes a 1/2 unf- or 3/8 unf stud at the top of the half-wave attachment; it’s screwed into a threaded hole at the output face of the coupler. In this case we have also used tuned titanium bolt. The bolt is mounted through the coupler; then the horn attachments are bolted to the coupler. The tuned bolt method is primarily used on composite horns that have two or more block horn / sonotrode attachments.

In addition to the extra metal and machining that’s required, composite horns have more design considerations than a standard ultrasonic horn / sonotrode. We always have to make sure the horn / sonotrode we are designing is balanced. But when we deal with composite ultrasonic  horns / sonotrodes, all of the ultrasonic horns / sonotrodes attachments have to be positioned evenly around the coupler, so the weight is evenly distributed. Sometimes the attachments are different lengths and different shapes, but you still have to keep the horn balanced.

But despite the added challenges in the design and manufacture of ultrasonic composite horns / sonotrodes, they have provided consistent performance and productivity for.

Sometimes a injected molded part cannot be welded without using of ultrasonic composite horn / sonotrode, therefore application can use a ultrasonic composite horn / sonotrode, the increase in productivity and the cost savings are so great that the initial added cost in tooling is more than justified.

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