Application of Finite Element Method in Design and Performance Evaluation of Ultrasonic Cutting Horn

Material cutting is one of the most widely used industrial processes, which is always accompanied by challenges. One of these challenges is the ability to cut materials with high elasticity such as rubber or soft and crispy materials such as cake. In order to increase the life of the tool and achieve a suitable and accurate cutting surface and achieve a high cutting speed, the technology of high power ultrasonic vibrations is used in the modern industries of tire and rubber production and food industries. The proper design of the ultrasonic cutting tool, guarantees the proper performance and the tool life. The design and manufacture of ultrasonic cutting horns is complicated due to the influence of various factors on the shape and dimensions of the part. In this article, the effect of the dimensional parameters of the horn design on two important output factors, namely the resonance frequency of longitudinal vibration mode and the uniformity of the vibrations of the front surface of the ultrasonic cutting horn made of titanium alloy, have been investigated and analyzed. The results have shown that by using design improvements in finite element software, it is possible to achieve a cutting horn with a frequency close to the nominal design frequency and with the highest uniformity of the vibration amplitude on the front surface of the horn.