Several conditions must be taken into account when designing sonotrodes, as a poorly designed sonotrode is not only short-lived, but also has a negative effect on the quality of the weld, which can also destroy the converter and the ultrasonic generator.When designing, the material quality, shape, size of the part to be welded, the operating frequency of the welding machine used for welding, and the amplitude delivered must also be taken into account. The material of the sonotrode to be manufactured must be selected in accordance with the conditions listed above. Like any object that can be vibrated and has its own resonant frequency, so does the sonotrode. The resonance must be consistent with the resonance of the converter and booster.
The material of the sonotrodes can be an aluminum alloy, titanium or a high-wear steel alloy.
One of the important functions of a sonotrode (sonotrode, horn) is to transmit the mechanical vibration produced by the ultrasonic generator and the converter to the workpiece. For this to succeed, the sonotrode must perfectly adapt to the shape of the workpiece to transmit vibration and welding pressure where it is most optimal. The other task is to amplify it to the required level if the converter and the mechanical amplifier (booster, ampli) are not able to provide the mechanical amplitude required for welding. The shape of the sonotrodes varies in a unique way according to the application, the shape and material of the workpiece to be welded.
Possible shapes: cylindrical, bell, knife, block, cylindrical-block, compound-pin, ….
A 3D model of the part is essential for design. If necessary, the surface copied from the part must also be etched into the sonotrode. If a welding nest is to be manufactured, a 3D model (in .step, .iges format) is also essential.
When designing the sonotrode, the material quality of the part to be welded, the operating frequency of the welding machine used for welding, and the emitted amputity must also be taken into account.
The material of the sonotrode to be manufactured must also be selected in accordance with the conditions listed above. In any case, the design also requires a 3D model of the parts (in .step, .iges format) to create the correct shape.
A poorly designed sonotrode can ruin the generator or the converter and itself. False frequency sonotrode also results in unreliable, scrap welds.
General commitment deadline:
Production of sonotrodes, from order or 3-5 weeks after the transfer of the required information, depending on the complexity. If necessary, if our workload allows, it can be reduced to 1.5-2 weeks at an additional cost.