Design Optimization of Two Diagonal Slotted Block Horn for Ultrasonic Plastic Welding

One of the inescapable techniques which are widely used in different engineering fields and manufacturing industry is ultrasonic plastic welding. It is recommended to make the design of the main components of ultrasonic technique to have high precision and good accuracy. Ultrasonic horn remains the main components, as this part is always working contact to the working area. Therefore, design and optimization of this tool become more essential due to large number of application. In this research a horn type block contain two slots was successfully designed and its dimensions were precisely optimized utilising from the principles of ANSYS finite element software package, theoretical calculation and mathematical analysis expression in order to conduct the requirements application of plastic welding. The three dimensional model analysis of the block horn was carried out to identified from many criteria such as allow the horn to vibrate in purely longitudinal manner relative to the frequency excitation of generator, normally 20 kHz, obtained acceptable tuning mode and avoidance from participating with other non tuned flexural and torsional modes, insure high sufficient displacement amplitude at working area and low stress concentration shift close to the area of zero deformation, getting high surface uniformity at block horn tip and ensure the horn having acceptable gain. High amplification of block horn with configuration of two slots was calculated using modal and harmonic analyses of simulation models, while optimization of designed horn was done through performing response surface methodology (RSM) matrix obtained from MINITAB software and further connected with genetic algorithm (GA) by aid using of MATLAB software code. The results inferred that good estimation and prediction of vibration amplitude for the exciting slotted block horn can help to ensure sufficient amount of energy delivered to the working area for any application referred to plastic welding.