Numerical Modeling of Roller Tools for Ultrasonic Welding of Thermoplastic Materials

mass and high quality production assembly parts. The most important and distinguished property of this method to other fabrics and plastic sewing methods is the minimum destruction of materials and fibers because the maximum produced heat occurs in the contact interface. Horn is one of the basic parts of the ultrasonic welding which in addition on the transmitting waves and appropriate energy concentration, provides the necessary pressure to keep the melted joint interfaces together in order to form a weld. The purpose of this paper is to study the design of a roller type tool by numerical method using finite element method. In this research, the design and modeling of continuous welding roller tools was performed using numerical finite element method by ABAQUS 6.12 software. By simulating and analyzing include natural frequency and harmonic analysis, the frequency, mode shape and other design parameters and behavior of the collection during applying oscillations for 4 types of horns include conical integrated, stepped with grooves integrated, stepped without grooves integrated and bell-like horn were derived. The result of the different horns shows that the stepped without groove horn has the highest gain, but the radial displacement distribution in the conical integrated and stepped with groove horns is more non-uniform than other horns. Also, in the stepped without groove and bell-like horn, the efficiency of the conversion of longitudinal to radial displacement and the uniform distribution of radial displacement is more uniform, which results in better optimal design conditions.