Sonotrode Mounting for Ultrasonic Additive Manufacturing
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Solution Overview
Problem
Current ultrasonic additive manufacturing (UAM) technology faces challenges with titanium-based tools that wear rapidly, leading to insufficient interaction and loss of displacement during the welding process, affecting bond quality, especially when dealing with materials like Ni, Ti, or high-speed steel.
Innovation Solution
An advanced sonotrode design featuring a mounting plate with force application regions, linear guides, and low-friction linear bearings that allow for flexible support and high-force transmission, enabling efficient energy transfer and rotation under high loads while maintaining surface texturing, reducing friction and power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If titanium-based tools are used in ultrasonic additive manufacturing, then the sonotrode can be manufactured with current technology, but the tool wears rapidly causing loss of displacement and insufficient interaction during welding
Solution Approach 1:
The patent changes the material parameter from titanium to advanced tool steels, which have superior wear resistance and maintain their mechanical properties under high static forces and ultrasonic vibration conditions, thereby preventing displacement loss and tool wear
Solution Approach 2:
The patent employs composite construction by integrating advanced tool steel materials into the sonotrode design, combining materials with different properties to achieve both high strength for force transmission and wear resistance for maintaining surface texturing over extended periods
2Strength
If higher static forces are applied to transmit increased ultrasonic energy, then weld strength is improved, but tool deflection increases affecting bond quality
Solution Approach 1:
The patent incorporates mounting plates with integrated linear guides and low-friction bearings before the welding process begins, pre-positioning the sonotrode in a stable configuration that can withstand high static forces without deflection, thereby maintaining bond quality throughout the welding operation
Solution Approach 2:
The patent introduces mounting plates, linear guides, and low-friction bearings as intermediary components between the ultrasonic stack and the sonotrode, which serve to stabilize the system, reduce friction, and prevent deflection while allowing high static forces to be transmitted effectively
3Device complexity
If conventional sonotrode mounting is used, then the structure is simple, but friction is high causing power loss and reduced efficiency
Solution Approach 1:
The patent replaces conventional high-friction mechanical mounting with low-friction linear bearings and linear guides, substituting a high-loss mechanical system with a low-loss system that maintains simplicity while dramatically reducing power consumption and increasing efficiency
Solution Approach 2:
The patent introduces dynamic elements including low-friction linear bearings and spring clamps that allow the mounting structure to adapt to operational conditions, reducing friction losses while maintaining structural integrity and simplicity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances the strength of welds, reduces linear void density, and allows for the bonding of higher-strength materials by applying increased static forces and ultrasonic energy levels, improving the overall performance and efficiency of the UAM process.
Implementation Method 1
an ultrasonic stack that includes a converter or piezoelectric transducer for converting the electrical signal into a mechanical vibration
Implementation Method 2
a sonotrode or horn for applying the mechanical vibration to the parts to be welded
Implementation Method 3
all three components of the stack are specifically tuned to resonate at the same exact ultrasonic frequency
Implementation Method 4
The ultrasonic vibrations of the sonotrode, which are parallel to the workpiece surfaces, create the relative frictionlike motion between the interface of the workpieces, causing the deformation, shearing, and flattening of surface asperities
Data Source
AI summary
An ultrasonic welding assembly, comprising: a sonotrode having a single welding region and two nodal regions formed on either side of the welding region; a mounting plate for supporting the sonotrode having a force application region on the upper surface thereof; at least one ultrasonic transducer connected to the sonotrode; at least one diaphragm spring disposed between the ultrasonic transducer and the sonotrode; at least one roller bearing connected to the diaphragm spring; at least two linear guides connected to the roller bearing, wherein the at least two linear guides are connected to the mounting plate and support the roller bearing and the sonotrode in a flexible manner; and first and second low-friction linear bearings in contact with nodal regions for the application of downward force to the sonotrode, wherein the first and second linear bearings are connected to the mounting plate.