Analysis of Exponential Horn in the Ultrasonic Machining Through Numerical Investigation

One of the more sophisticated machining techniques, ultrasonic machining, is used to cut brittle and delicate materials including glass, ceramics, and graphite. The most crucial element is the ultrasonic trumpet. A transducer was utilized to transmit the longitudinal mode of vibration to the ultrasonic tool. In work, two distinct titanium-based ultrasonic horn profiles were created and put to the test in a fast-paced setting. To determine the mode shapes and the natural frequencies of both horn profiles, a modal analysis will be performed. ANSYS 18.1 workbench interface is used to do the analysis. The workbench interface uses the harmonic response analysis to simulate the stress and deformation behavior of both horn profiles. A defect is then introduced to the horn's design at the main point of stress once the tensions have been determined. The defects can appear in a variety of directions, including parallel to the longitudinal axis and angled with respect to the horn's oscillation. The defect parallel to the longitudinal axis is subjected to the highest strains in relation to the oscillation of the horn. The results of this simulation can be utilized to determine how the horn will behave in the event of an ultrasonic machining error. The behavior of the horn when there is a deficiency may be examined thanks to this research.