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Assessing a stepped sonotrode in ultrasonic molding technology

Ultrasonic molding is a new technology used to process polymeric micro-molded parts. An ultrasonic horn, or sonotrode, transmits ultrasonic energy which melts the material and pushes it into a mold cavity to configure a shape. Sonotrode design - and any transformations to the dimensions or shape caused by tool wear - strongly affects efficient operation. The sonotrode may go beyond the generator operating frequency range, thus affecting process performance. This paper assesses two issues involving a stepped sonotrode employed in ultrasonic molding: (i) a design procedure that can predict the sonotode’s behavior during the molding process and (ii) a method for creating a sonotrode operating frequencies map which will facilitate the design of new sonotrodes and be able to determine the extent to which they can be re-machined after a certain period of wear. Numerical simulations carried out by finite element methods were compared to experimental measurements performed to capture the sonotrode frequency vibrational modes. A frequency map provides the dimensional range within which the sonotrode can be re-machined in order to eliminate tool wear and allow the sonotrode to work properly again, thus extending the lifecycle of the tool

This project was carried out with the helpof a DPI2013-45201-P reference grant awarded by the Spanish Gov-ernment

© Journal of Materials Processing Technology, 2016, vol. 229, p. 687-696

Elsevier

Author: Grabalosa Saubí, Jordi
Ferrer Real, Inés
Martínez-Romero, Oscar
Elías-Zúñiga, Alex
Plantá, X.
Rivillas, F.
Date: 2016 March
Abstract: Ultrasonic molding is a new technology used to process polymeric micro-molded parts. An ultrasonic horn, or sonotrode, transmits ultrasonic energy which melts the material and pushes it into a mold cavity to configure a shape. Sonotrode design - and any transformations to the dimensions or shape caused by tool wear - strongly affects efficient operation. The sonotrode may go beyond the generator operating frequency range, thus affecting process performance. This paper assesses two issues involving a stepped sonotrode employed in ultrasonic molding: (i) a design procedure that can predict the sonotode’s behavior during the molding process and (ii) a method for creating a sonotrode operating frequencies map which will facilitate the design of new sonotrodes and be able to determine the extent to which they can be re-machined after a certain period of wear. Numerical simulations carried out by finite element methods were compared to experimental measurements performed to capture the sonotrode frequency vibrational modes. A frequency map provides the dimensional range within which the sonotrode can be re-machined in order to eliminate tool wear and allow the sonotrode to work properly again, thus extending the lifecycle of the tool
This project was carried out with the helpof a DPI2013-45201-P reference grant awarded by the Spanish Gov-ernment
Format: application/pdf
ISSN: 0924-0136
Document access: http://hdl.handle.net/10256/13164
Language: eng
Publisher: Elsevier
Collection: MINECO/PE 2014-2016/DPI2013-45201-P
Reproducció digital del document publicat a: http://dx.doi.org/10.1016/j.jmatprotec.2015.10.023
Articles publicats (D-EMCI)
Is part of: © Journal of Materials Processing Technology, 2016, vol. 229, p. 687-696
Rights: Tots els drets reservats
Subject: Anàlisi modal
Modal analysis
Ultrasons -- Aplicacions industrials
Ultrasonic waves -- Industrial applications
Title: Assessing a stepped sonotrode in ultrasonic molding technology
Type: info:eu-repo/semantics/article
Repository: DUGiDocs

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