Sonotrode design / production
Several factors must be taken into account when designing sonotrodes, because a poorly designed sonotrode is not only short-lived, but also negatively affects the quality of welding, and can destroy the converter and the ultrasonic generator. When planning, attention must be paid to the material quality, shape and size of the part to be welded, the operating frequency of the welding machine used for welding, and the output amplitude.
The material of the sonotrode to be manufactured must be selected in accordance with the conditions listed above. Like all objects that can be made to vibrate and have their own resonance 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: aluminum alloy, titanium alloy, or high wear-resistant steel alloy.
One of the important tasks of the sonotrode (sonotrode, horn) is to transfer the mechanical vibration produced by the ultrasonic generator and converter to the workpiece. In order for this to succeed, the sonotrode must adapt perfectly to the shape of the workpiece to transmit the vibration and welding pressure where it is most optimal. Its other task is to amplify it to the required level if the converter and the mechanical amplifier (booster, amplifier) cannot provide the mechanical amplitude required for welding. The shape of the sonotrodes varies according to the application, the shape and material of the workpiece to be welded.
Possible forms: cylindrical, bell, knife-shaped, block, cylindrical-block, compound-pin, ….
A 3D model of the component is essential for planning. If appropriate, the surface copied from the component must also be milled into the sonotrode.
If a welding nest is also to be produced, the 3D model (in .step, .iges format) is also essential.
When designing the sonotrode, attention must be paid to the material quality of the part to be welded, the operating frequency of the welding machine used for welding, and the output amplitude.
The material of the sonotrode to be manufactured must also be selected in accordance with the conditions listed above. For the design, the 3D model of the parts (in .step, .iges format) is also necessary in order to create the correct shape.
A poorly designed sonotrode can destroy the generator or the converter and itself. A sonotrode operating at a false frequency also results in unreliable, scrap welds.
Welding Nest design, production
The welding nest (ambos, jig, …) is also an important element of the system. He must fix and support the workpiece on as large a surface as possible. The nest perfectly surrounds the figure, preventing it from vibrating or moving. Its own resonance must be far from the welder’s operating frequency. If necessary, it is equipped with manual or automatic closing and component fixing. It communicates with the PC/PLC controlling the process.
The surfaces of the welding nest adapt to the surface of the work piece in order to support and fix the work piece to be welded as perfectly as possible. Therefore, for the design of complex geometries, 3D models of the workpieces in .step or .iges format are needed.
So, an accurate drawing of the workpiece is not only necessary for the design of the sonotrode, but also essential for the design and preparation of the welding nest !!
General commitment deadline:
The production of the welding nest, from the order, or 3-5 weeks after providing the necessary technical information, depending on the complexity.
In appropriate cases, if our workload allows, it can be reduced to 1.5-2 weeks for an additional fee.
During the irradiation, the sonotrodes perform a pulsating movement in their entire material volume and structure. Because of this, they are exposed to a lot of stress. In addition to failure, it also causes welding and quality problems.
If the sonotrode does not vibrate with the same amplitude at the welding surfaces, the component is not exposed to the same thermal effect, and the quality of the welding is not the same. Leakage and bond strength problems. If we weld the workpiece more strongly to avoid this, we experience overwelding elsewhere, or sometimes the workpiece is damaged or deformed. This can be avoided with subsequent optimization.
First step, the exact drawing of the sonotrode, possibly a 3D model (in .step, .iges format). The manufacturer, type, frequency of the welding machine and the material of the sonotrode are essential information. The sonotrode is then subjected to virtual inspection (FEM). The sonotrode is tested in terms of frequency, amplitude distribution and material stress. This is of course subject to a fee. Then, if physical optimization is possible, we will make an offer.
The physical intervention and control takes approx. It takes 4-8 working days, depending on workload.
A poorly designed and sized sonotrode can destroy the sonotrode itself, the converter and the generator.