Sonotrode production

Sonotrode Design / Manufacturing

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.

There are also special tools with large, complex and intricate constructions for performing special tasks.

Sonotrode design, sonotrode production

WELDING SAW DESIGN, MANUFACTURE.

The welding socket (ambos, jig, …) is also an important part of the system. He must fix and support the workpiece on as large a surface as possible. The nest perfectly surrounds the part, preventing it from vibrating, moving. Its own resonance must fall far from the operating frequency of the welder. If necessary, it is also equipped with manual or automatic closing, component locking. Communicates with the process controlling PC / PLC.

The surfaces of the welding socket adapt to the surface of the workpiece to support and secure the workpiece to be welded as perfectly as possible. Therefore, the design of complex geometries requires a 3D model of the workpieces in .step or .iges format.

So, not only is an accurate drawing of the workpiece required for the design of the sonotrode, but it is also essential for the design and fabrication of the welding nest !!

Commitment deadline in general:

Production of the welding socket, from the order or 3-5 weeks after delivery of the required technical information, depending on the complexity. If necessary, if our workload allows, it can be reduced to 1.5-2 weeks at an additional cost.

Welding nest manufacturing

welding socket design, welding socket manufacturing

Sonotrode optimization

During the irradiation, the sonotrodes perform a pulsating motion in their entire extent and structure. Because of this, they are exposed to high loads. 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 part is not exposed to the same heat, the welding quality is not the same. Leakage, causes bond strength problems. If we weld the workpiece harder to avoid this, we will experience over-welding elsewhere, resp. in some places the workpiece is damaged and deformed. This can be avoided by post-optimization. First step, an accurate drawing of the sonotrode, possibly a 3D model (.step, .iges format). The manufacturer, type, frequency and material of the sonotrode of the welding machine are also essential info. The sonotrode is then virtually inspected (FEM). The sonotrode is tested for frequency, amplitude distribution, material voltage. This is of course a fee. Then, if physical optimization is possible, we make an offer. Physical intervention and control takes approx. It takes 4-8 business days, depending on workload.

A poorly designed, scaled sonotrode can also damage the sonotrode itself, the converter, and the generator.

Image of poorly sized sonotrode

Resonant but not optimized sonotrode

Optimized amplitude

sonotrode design, sonotrode manufacturing, sonotrode optimization