2) Transverse cross-section shape round, rectangular, etc. The tolerance is usually around 0,25% of the nominal frequency (50 Hz @ 20 kHz). Sonochem., 2007. 3) Frequency and tolerance range. Horns with constant stress [10] have both comparatively large amplitude and small stress. Give us a call today to get your free estimate! However this is planned for SonoAnalyzer Pro where an analysis server can be dedicated to a single user. Piezoelectric ceramics (PZT-4), 7075-T651 aluminum, 303 stainless steel, and TC4. 15) How to design ultrasonic horns / sonotrodes? 1) What are the Fa, Za, Fr, Zr and Fc parameters for? Be confident that your fencing projects are in the hands of experts. 6 shows the frequency of 56kHz as well as the 3 inherent modes surrounding it, including bending vibration (Fig. 9. ), the preferred ultrasonic horn type is the Barbell horn. Non-dominated sorting genetic algorithm is used to the optimization of the horn profile. "Ultrasonic Horn Designs and Properties", Industrial Sonomechanics website, 2011, "Barbell Horn Ultrasonic Technology", Industrial Sonomechanics website, 2011, "Ultrasonic Liquid Processor Systems", Industrial Sonomechanics website, 2011, https://en.wikipedia.org/w/index.php?title=Ultrasonic_horn&oldid=820940378, Creative Commons Attribution-ShareAlike License 3.0, This page was last edited on 17 January 2018, at 14:10. Input amplitude is set by the user on the Analysis tab ("Input p-p"). 2) Why do some ultrasonic equipment operate at resonance and others at antiresonance frequency? Once they got to work on the actual installation, I knew they were the best contractors around with great value for my dollar. Contour plots of displacement and axial-displacement (which considers only the component of displacement in the axial direction) display the variation in amplitude across the entire sonotrode. They are far different from surrounding modal frequencies (exceeding 8%). With the functions of amplitude amplification, impedance matching and protecting the transducer in ultrasonic machining system, ultrasonic horn is an important component in design of power ultrasonic vibration system. With the development of computer technology and the perfection of finite element theory, making use of finite element can not only accurately calculate the various parameters of complicated shaped horns, but also simplifies the calculation process significantly. Table1 shows the comparison of advantages and disadvantages of commonly used horns. The working frequency of Langevin vibrator is 53.7 kHz, and it works under first-order longitudinal vibration mode. Fig. 5) What is the mechanical quality factor Qm and what is it for? Its amplitude was measured under the microscope. Therefore, its not applicable to ultrasonic applications with large amplitude [10]. 11. With a variety of designs to choose from, our team can install the wood fence that would complement your home and add value to it. 6(b)) and torsional vibration (Fig. [1] Ultrasonic processing of liquids relies of intense shear forces and extreme local conditions (temperatures up to 5000 K and pressures up to 1000 atm) generated by acoustic cavitation.[2]. Horn with large amplitude are increasingly widely applied in various ultrasonic applications, such as ultrasonic operation [2], ultrasonic motor [3], ultrasonic wave lubrication [4] and ultrasonic welding [5] etc. 14(b) show the vibration conditions of the ends of the Bezier horn under static state and resonant state as observed by microscope. Were not experts of any kind when it comes to construction, so thankfully these guys were able to steer us in the right direction just by asking us a few questions. The diameters of the top and the end are D1 and D2, its length is L. Fig. Fig. 3)Perform selection from the parents and the offspring: once the population is sorted based on the non-dominated sorting algorithm, only the best solutions are selected. At Continental Fence, we take great pride in providing excellent communication, reliable service, and professional fence installation in Schaumburg every time were called upon. The actually measured frequency is very close to the theoretical frequency. The profile of the horn is a cubic Bezier Curve. For fence contractors in Schaumburg who get the job done quickly and at a good price, well always choose Continental. Schematic of Langevin vibrator and horn. However, when the excitation frequency of the system approaches to 53.87 kHz, the second-order longitudinal frequency will not be excited. Fig. The sinusoidal signal output by the signal generator (RIGOL DG1022) was switched in the vibrator via power amplification (LM3886). This type of fence may be a bit more pricey than any other kinds of fences. Learn more about tuning of ultrasonic horns. However in some cases (mostly more complex designs like blocks and rings), alternative modes exist that: Such modes can severely compromise the sonotrode design, potentially making it completely useless. 4)Replace the unfit individuals with the fit individuals to maintain a constant population size. By examination of the mode shapes, decide which resonance mode will work best for your application (commonly the half-wavelength axial mode as discussed above). This peak-to-peak value of displacement is commonly used in the ultrasonics industry and often misnamed "amplitude peak-to-peak". However, horns with constant stress are more complicated and are expensive in terms of both design and processing. 17, Issue 3, 2015, p. 1157-1168. The figure shows that the amplitudes of the horns all increase with the increase of the voltage. The lower limit on ultrasonic frequencies is generally taken as around 18 to 20kHz. Comparison of the four types of the horns. Fig. Simulation comparison was also carried out on the vibration performances of other four kinds of horns. and Peshkovsky, A.S., "Matching a transducer to water at cavitation: Acoustic horn design principles", Ultrason. Converging ultrasonic horns are also commonly included in laboratory liquid processors used for a variety of process studies, including sonochemical, emulsification, dispersing and many others. Theoretically, the amplitude of horns with equal stress is larger than that of stepped-shaped horn. This is an open access article distributed under the, Large amplification coefficient of amplitude, Stress concentration, prone to fracturing, Comparatively small amplification coefficient of amplitude, Simple design and processing, comparatively low cost, Comparatively large amplification coefficient of amplitude, comparatively uniform stress distribution, Medium amplification coefficient of amplitude, Maximum shape factor, the maximum amplitude can be acquired theoretically, Comparatively complicated design and processing, comparatively high cost, Good matching of amplification coefficient of amplitude and stress distribution, Comparatively complicated design and processing, high cost, Advantages and disadvantages of several commonly used horns, Bezier profile curve and its four control points, a) Schematic of assembly, b) mesh generation for three-dimension finite element model, Piezoelectric ceramics (PZT-4), 7075-T651 aluminum, 303 stainless steel, and TC4, Three modes surrounding the working frequency, Population distribution of several generations in the optimization design, Distribution of vibration displacements along the normalized length of the horns, Equivalent stress distribution along the normalized length of the horns, Comparison of the four types of the horns, Model of Bezier horn and Langevin vibrator system, Schematic diagram of the experiment for ultrasonic horn, Comparison between the static and dynamic vibration, Relationship between the vibration amplitude and voltage. This does vary for different sonotrodes so treat it just as an initial figure - use your own results to find a suitable value for each new design. This assumption was verified in subsequent experiment. Commonly used horns mainly include stepped-shaped, conical, exponential and Gaussian-shaped [12] horns. For a few specific profiles, the step-up ratio can be easily calculated. As the amplitude exceeds 10m, the amplitude can be directly observed at the vibration end face with long-focus microscope. 1)Select the parents: parents, which are fit for reproduction, are selected for reproduction to generate offspring. Mr. H.P.G. For stepped-shaped horn, its stress mutation reaches the maximum value at the area mutation position. The vibration mode of the transducer was analyzed by ANSYS software to obtain the frequency and vibration conditions of the horn. Abromov [12] pointed out that under the same shape factors, the amplitude amplification coefficient of a conical horn is larger than that of an exponential horn and less than that of a stepped-shaped horn. It's much faster and cheaper to test new designs in a computer than to manufacture and test a real, physical sonotrode. The horn was manufactured by means of numerical control technique (NC). So if you already have equipment operating at, say, 20kHz +/- 200Hz, you must design and manufacture your sonotrodes to resonate at a frequency in the range 19800 to 20200 Hz. The individual with better fitness is selected as a parent. The experiment shows that when the excitation voltage is less than 160Vp-p, the average amplitude of Bezier horn is 73.5% larger than that of the conical horn. 13. Ultrasonic assembly of thermoplastic moldings and semi-finished products - Recommendations on methods, construction and applications. Distribution of vibration displacements along the normalized length of the horns, Fig. However, the calculation results were not improved. 2)Perform crossover and mutation operator on the selected parents: the algorithm uses simulated binary crossover and polynomial mutation. ZVEI. Parameterization curve can flexibly adjust the cross-section shape of the horns by adjusting various parameters, thus obtaining the horns with required amplitude ratio and frequency. 15: p. 618628. Continental Fencing offers many styles of fence and will work with you to find the one that is right for your budget. Our team is happy to discuss your fencing needs. As shown in Fig. Check the resonant frequency of this mode - do you need to adjust it up or down to suit the working frequency of your equipment? Fig. 9 shows the curve of distribution of vibration displacements along the normalized length of the horns based on finite element calculation. The schematic diagram of the measurement device is as shown in Fig. 1. Under the excitations of corresponding resonant frequencies, the relationship between the two horns and the voltage is as shown in Fig. a) Schematic of assembly, b) mesh generation for three-dimension finite element model. Note: The welding joint should also be projected with energy concentrators to reduce the amplitude of vibration and energy required to perform the welding. 692. In SonoAnalyzer the input is typically at the top of the sonotrode diagram in the Dimensions tab and the output at the bottom. With our affordable prices and unbeatable quality of service, our customers love the fact that they can always count on us for a job well done. For quick service and reliable work, there simply isnt a better choice for homeowners in the greater Chicago area, from Evanston to Palatine, Deer Park to Mount Prospect, and Lake Zurich. Fig. Select your chosen working mode and then from the menu choose FEA -> Download Stress Plot. However, we have limited experience in designing sonotrodes. 3, pp. [3][5] A composite ultrasonic horn has a transitional section with a certain longitudinal cross-section shape (non-cylindrical), positioned between cylindrical sections. Some models have restrictions on geometry such that the output is always smaller (or at least, no bigger) than the input, so the step-up ratio will always be greater than or equal to one. It shows that the amplitude amplification of the designed Bezier horn is about 1.73 times as large as the amplitude amplification of the conical horn. Sonotrodes (ultrasonic horns) and boosters are special tools designed so that their natural vibrations (resonance) form a defined mode shape at a particular frequency. The vibration amplitude of the Bezier horn and conical horn are measured by optical microscope and relevant software. To acquire a new ultrasonic horn with large amplitude amplification ratio, the profile of the horn was designed to be a cubic Bezier Curve. So for example, if a transducer which delivers an amplitude of 10 microns is fitted to the input of a 2:1 booster, the amplitude at the output of the booster will be 20 microns. The maximum value of stress, shown as "max" towards the top-left of image (units are SI, so stress in Pascals). He was so friendly and answered all my questions, really putting my mind at ease. To test the sonotrode frequency, one can use our test instrument, TRZ Analyzer. The figure will usually be relevant only for the chosen, working mode. If adjustment is required, change a dimension accordingly. Frequency and its respective tolerance should be compatible with the power generator specs and also depends on the parts geometry, size and material. Flowchart of the optimization procedure. In the design, each individual was subject to modal analysis and harmonic response analysis, and the first-order resonant frequency f0 and amplitude amplification ratio M were obtained. Before modal analysis, point coupling was carried out on the surface of piezoelectric ceramics, with voltage applied. Ultrasonic horns may be classified by the following main features: 1) Longitudinal cross-section shape stepped, exponential, conical, catenoidal, etc. The actual working frequency is slightly less than the frequency of finite element simulation due to many reasons: (1) the difference between actual and theoretical properties of the material, such as density and Youngs modulus, (2) errors due to processing, (3)failing to consider damping during simulation, but there is certain damping. Design of a 20 kHz cylindrical ultrasonic horn that can be tuned with the TRZ Analyzer. In the calculation, N= 40, 50, 60, 70 and 80 were also calculated. When Auto tuning is used, the frequency display on the Dimensions tab becomes writable, and this is used to set the required working frequency. Under the same excitation, the average amplitude of Bezier horn is 73.5% larger than that of conical horn. and Peshkovsky, A.S., "Shock-wave model of acoustic cavitation", Ultrason. Why choose a company from out of town when Continental is your convenient, local, high-quality service provider? ie. SonoAnalyzer allows users to predict such problem modes and alter the design to move their frequencies either up or down, away from the working frequency. Peshkovsky, S.L. 15. In the range of 0-100kHz, the transducer system composed of vibrator and horn also presents other response modes. The other models (labelled "Online FEA") are far more versatile because they perform a full FEA analysis of the exact model requested by the user but this also makes them slower, often taking 30 seconds to a minute or more per analysis run. Consumer products, automotive components, medical devices and most all industries utilize Ultrasonics. The stress of Bezier horn is comparatively small and uniform compared with that of others. This type of fence can be cost-efficient, especially if you install it with our own customized design and can also personally add a nice touch to your home. 6. To carry out comparison, conical horn was processed and measured simultaneously, with the resonant frequency of 53.65kHz. The parameters of the materials are as shown in Table2. Frequently, an ultrasonic horn has a transitional section with a longitudinal cross-section profile that converges towards the output end. The horizontal ordinate is f=f-f0, and the vertical coordinates is amplitude amplification ratio, i.e., the ratio between the amplitudes at the top and the end of the horn. 6(a)), longitudinal vibration (Fig. It also has the flexibility of designs and dimension that can matches what you have in mind. It was a constant value of 53.7 kHz. 4. So the aim is to create a design that meets any specific requirements of your process and is resonant in the desired mode of vibration at the nominal working frequency. It was manufactured by numerical control technology. Equivalent stress distribution along the normalized length of the horns, Table 3. Next time youre in need of fencing or help with your entry system, give us a call and experience great customer service. Copyrights 2016 Renew | All rights reserved. eg. Metal inserts may be secured in plastic and dissimilar materials can often be bonded with proper tooling design. There is only one resonance peak in the analysis frequency range, which is conducive to restraining other vibration modes in the system from disturbing the required vibration mode. 14. 1) Geometry; The ultrasonic horn is commonly a solid metal rod with a round transverse cross-section and a variable-shape longitudinal cross-section - the rod horn. To develop a sonotrode, you should first establish the basic requisites: Maximum achievable ultrasonic amplitude depends, primarily, on the properties of the material from which an ultrasonic horn is made as well as on the shape of its longitudinal cross-section. Frequency response curves of the horn. The step-up ratio has already been discussed but that is a single figure based on average amplitude - in the case of larger sonotrodes, particularly blocks, the amplitude may vary considerably across the output surface, to the detriment of the process. Here at, Nothing adds a touch of class and style to your home than a custom built wood driveway gates which, Now if you would prefer a more durable fence for your home, ornamental metal fencing is the choice for you. Three modes surrounding the working frequency. 10. Service Area of Continental Fence Contractors, Testimonials of Continental Fence Company. Fig. 11571168, May 2015. In SonoAnalyzer, calculate all its resonant modes and frequencies. Its obvious that the amplitude of longitudinal vibration with the frequency of 63.80kHz is larger than the amplitude of the vibration with the frequencies of 53.87 kHz and 82.43kHz. Various parameters of the horns can be obtained by traditional analytical methods subject to complicated calculation [17]. Fig. The profile of the horn is a cubic Bezier Curve. The device is necessary because the amplitudes provided by the transducers themselves are insufficient for most practical applications of power ultrasound. Choose Continental Fence For the Most Professional Fence Contractors in Schaumburg. 2. However, other modal responses are small, so only the 3 longitudinal resonant modes among them are given. In reality this is always false - any sonotrode will have an infinite number of different modes and frequencies, some of which (those towards the lower end of the frequency range, or close to the working frequency) should definitely be considered as part of the design process. the full-wavelength axial mode (as the name implies, effectively two half-wavelength sonotrodes joined together). Schematic diagram of the experiment for ultrasonic horn. Bezier horn and conical horn were manufactured by numerical control (NC) technology, in addition, measurement and comparison were carried out on their performances by combining with a vibrator. The horn is axisymmetric. The model of the optimized horn was built by UG, which was assembled with vibrator, as shown in Fig. Abramov, O.V., "High-intensity ultrasonics: theory and industrial applications", 1999: CRC Press. In this paper, a new ultrasonic horn with large amplitude is designed based on Bezier parameterized curve. Some boosters are reversible and in this case the step-up ratio is inverted - a 2:1 booster in reverse will work as a 1:2 step-down, or a step-up of 0.5. Under the excitation voltage of 200Vp-p, the amplitude of the Bezier horn can reach 108m. The transducer system composed of Langevin vibrator and Bezier horn is processed and measured. A new horn with large amplitude is designed. They were courteous and professional, really taking the time to work with us and understand the details of the job and their craftmanship was superb. The genetic algorithm uses a binary tournament selection and the crowded-comparison operator. 14(a) and Fig. During the optimization, the working frequency f, radiuses (R and r) at the top and end of the horn as well as the L are defined first. Thus, the horns longitudinal oscillation amplitude increases towards the output end, while the area of its transverse cross-section decreases. In, Custom-built wood fence panels allow homeowners to lampposts, gates or even outdoor lighting. The cubic Bezier Curve is determined by the following four points: starting point M0, control point of starting point M1, control point of end point M2 and end point M3, as shown in Fig. The optimization design is carried out by means of Non-dominated Sorting Genetic Algorithm which can be used for solving multi-objective constraint problems. We do not sell software for this application, but you can use any software with dynamic analyses (for instance, SolidWorks), or analytical equations for basic geometries. In the mesh generation, the element type of piezoelectric ceramic ring is 20-node hexahedral solid226, while other parts are 20-node hexahedral solid95. Bezier Curve is shown as follow: where t is the parameter, x0-x3 and y0-y3 are the lateral and longitudinal coordinates of point M0-M3 respectively. Repeat the process from step 1 with the new dimensions, until you end up with a design that puts your chosen mode at the desired working frequency. Comparison between the static and dynamic vibration, Fig. 8 shows an optimized Bezier horn acquired as well as the positions of its four control points. designed an exponential horn by exponential function. The research integrates the methods such as finite element and optimization design etc., which is conducive to providing new thought for designing ultrasonic horn. a million cycles in only 50 seconds of operation at 20kHz) so fatigue is the most likely mode of failure and stress must be kept below the fatigue limit for the material used. The curve of detailed stress and displacement distribution were obtained. Peshkovsky, S.L. Large amplitude ratio can be acquired and its easy to process. The piezoelectric ceramics are made of four piezoelectric ceramic rings polarizing along z direction. Surface treatment (peening / polishing) may be used in that region to improve durability and the more advanced profiles (eg. The horn of this shape not only has large amplitude, but also has small stress distribution. 16 shows the frequency response curves of the horn in simulation and experiment. We chose Continental Fence on the recommendation of a colleague and it was an excellent decision. 13. This is very close to the results from simulation (Table3). Keywords: ultrasonic horn, vibration amplitude ratio, genetic algorithm, Bezier Curve. Fig. Through comparison, its obvious to judge that the vibration of the horn is longitudinal vibration, while bending vibration and torsional vibration are very small. In ultrasonic systems the number of vibration cycles mounts up very quickly (eg. 1900 E Golf Road #950, Schaumburg, IL 60173. For axial modes the length of the sonotrode is most important - increasing length will reduce the resonant frequency, and vice versa. Fig. 4(a) shows the Langevin vibrator and Bezier horn as well as their three-dimensional sizes. Over 20 years of quality fence building! The horn is made to work under first-order longitudinal vibration mode by reasonably designing its shape. The sonotrode should provide amplitude of vibration with uniformity and free of coupled lateral modes. We recently had Continental Fence handle our fence installation in Schaumburg and it was a fantastic experience, all around. The stress plot (a direct output from the Finite Element program) opens in a new tab. We use the latest tools and equipment to complete your projects on time and within budget. You can see the modes of vibration, which helps in understanding which one(s) will work for your process. 16. The amplitude of vibration and wear resistance should be compatible with the materials of the parts to be welded. [7] Barbell horns are able to amplify ultrasonic amplitudes while retaining large output diameters and radiating areas. Wed been looking around for a while before settling on these guys but were immediately struck by how well they handled every part of the job. Population distribution of several generations in the optimization design, Fig. FAQ: Do you sell some software for ultrasonic horn design? 12. a straight cylindrical sonotrode will always have a 1:1 ratio, a simple stepped sonotrode will have a step-up proportional to the inverse of the area ratio (diameter squared), and a pure exponential sonotrode will have a step-up proportional to the inverse of the diameter ratio. The simplest example is the axial-mode half-wavelength sonotrode. Dont take our word for it though, listen to what our satisfied customers have to say! Fig. Here at Continental Fencing, we staff professional installers with years of experience. Relationship between the vibration amplitude and voltage, Fig. If a step-down sonotrode is to be designed, this can still be achieved by designing the inverse (step-up) sonotrode and reversing the input / output faces. Table 1. The horn with the maximum amplitude ratio under certain frequency was acquired by multi-objective optimization design genetic algorithm. Therefore, these interferential modes are assumed as not existing in actual work. According to the figure, when the algorithm enters the 30th generation, the amplitude amplification ratio will increase significantly. Admittance and phase curve. Our aim is for you to own a wood fence and enjoy it for years to come. We have experience in assisting our customers with sonotrodes replication and preventive and corrective maintenance (we offer this assistance along with our test instruments). Vinyl is another popular choice of our customers because it is very low maintenance which makes the life of our homeowners easier as time passed. 8 also lists the profile curves of these three horns. In many cases end-of-life is caused by fatigue cracks at the highest-stress locations. The most common and simple to make transitional section shapes are conical and catenoidal. Results show that the amplitude of the optimized Bezier horn is 73.5% larger than that of conical horn. The crowded-comparison operator guides the selection process at the various stages of the algorithm toward a uniformly spread-out Pareto-optimal front. To avoid confusion while viewing the 3D display (which can be rotated to any orientation) the input surface is shown by a green-coloured region and the output is shown in orange.