How to design ultrasonic welding heads according to different application scenarios?

Designing ultrasonic welding heads to adapt to different application scenarios requires considering multiple key factors. The following are some basic design steps and key points:

1. Clarify application requirements

-Determine the type of material to be welded (such as plastic, metal, composite materials, etc.), understand its physical and chemical properties, including melting point, hardness, elastic modulus, etc.

-Determine the shape, size, and geometric shape of the welded product and the welding location.

-Clearly define quality requirements such as welding strength and sealing.

2. Choose the appropriate vibration mode

-The common vibration modes include longitudinal vibration, torsional vibration, and bending vibration. Select the most effective vibration mode based on the application scenario and welding materials.

3. Determine the geometric shape of the welding head

-The shape should match the welding area to ensure that energy can be evenly transmitted to the welding area.

-For complex shaped welded parts, it may be necessary to design special shaped welding heads, such as wedges, triangles, circles, etc.

4. Calculate the size of the welding head

-Based on the frequency and wavelength of ultrasound, calculate the length, width, and thickness of the welding head to achieve resonance and maximum energy output.

-Considering the propagation and attenuation of sound waves in the welding head, design the dimensions reasonably to reduce energy loss.

5. Select welding head material

-Common materials include titanium alloy, aluminum alloy, tool steel, etc. The selection of materials depends on the requirements of the application scenario, such as wear resistance, corrosion resistance, hardness, and cost.

-For high-strength welding requirements, it may be necessary to use stronger materials.

6. Design acoustic matching layer

-In some cases, in order to improve energy transfer efficiency, it is necessary to add an acoustic matching layer between the welding head and the transducer.

7. Conduct finite element analysis (FEA)

-Simulate and analyze the designed welding head using professional software to predict its vibration characteristics, stress distribution, and temperature distribution.

-Optimize and improve the design based on the analysis results.

8. Manufacturing and Testing

-Using appropriate processing techniques to manufacture welding heads, such as CNC machining, electrical discharge machining, etc.

-Conduct actual testing on the manufactured welding head to check if the welding quality and performance meet the requirements.

9. Optimization and adjustment

-Based on the test results, necessary optimization and adjustment should be made to the design of the welding head until the best welding effect is achieved.

In summary, designing ultrasonic welding heads is a complex process that requires comprehensive consideration of multiple factors and continuous optimization based on practical experience and experimental testing to meet the specific needs of different application scenarios.