Sonotrode Vibration Conversion for Low-Longitudinal Ultrasonic Machining

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Solution Overview

Problem

Existing ultrasonic machining technologies generate undesirable longitudinal vibrations that can damage workpieces and require complex designs to minimize these components, leading to inefficiencies and increased costs.

Innovation Solution

An ultrasonic component, such as a sonotrode, converts longitudinal vibrations into transverse vibrations using a conversion structure and reduces longitudinal components with a damping structure, allowing for efficient and cost-effective machining with minimal longitudinal vibration transmission.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If longitudinal vibrations are introduced into the sonotrode body, then ultrasonic vibrations are generated for machining workpieces, but longitudinal vibration components are transmitted to the machining side which can damage workpieces and cause undesirable damping

Engineering Contradiction:

Improveworkpiece integrityVSAvoidlongitudinal vibration damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent converts the harmful longitudinal vibrations into beneficial transverse vibrations at the machining side through a conversion structure. The conversion structure transforms the vibration mode so that the harmful longitudinal components are eliminated while the useful transverse components are enhanced for effective machining.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The damping structure acts as an intermediary between the sound introduction side and the machining side. It selectively absorbs and dampens longitudinal vibration components while allowing transverse vibration components to pass through, thereby protecting the workpiece from longitudinal vibration damage.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If a conversion structure is added to convert longitudinal vibrations into transverse vibrations, then the ratio of transverse to longitudinal vibrations is improved, but the device complexity increases

Engineering Contradiction:

Improvevibration ratio controlVSAvoidstructure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The conversion structure and damping structure are integrated into a unified design where the conversion structure performs both the vibration mode conversion and works in conjunction with the damping structure. This merging of functions reduces the number of separate components needed while achieving the desired vibration control.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent achieves vibration conversion by changing the physical parameters of the sonotrode body, such as its geometry and material properties, rather than adding complex external mechanisms. By optimizing the sonotrode's structural parameters, the conversion from longitudinal to transverse vibrations is achieved efficiently.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If a damping structure is added to reduce longitudinal vibrations, then workpiece damage is minimized, but the device complexity and manufacturing cost increase

Engineering Contradiction:

Improveworkpiece protectionVSAvoidmanufacturing simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The damping structure is implemented with local quality by positioning it specifically at the machining side of the sonotrode body where longitudinal vibration damping is most needed. The damping structure's properties are optimized for its specific location and function, allowing effective damping without requiring the entire sonotrode to be overly complex.

Inventive Principle:

Principle #3Local quality

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

The solution achieves stable and reliable machining with a high ratio of transverse to longitudinal vibrations, minimizing damage and complexity while maintaining efficient operation.

Implementation Method 1

A conversion structure is arranged between the sound input side and the processing side. This conversion structure allows transverse vibrations to be generated from the introduced longitudinal vibrations, with a vibration component in a plane perpendicular to the longitudinal axis.

Methodology Applied

Scientific EffectVibration conversion: Vibration

Implementation Method 2

A damping structure is provided between the conversion structure and the machining side. The damping structure is designed to reduce longitudinal vibrations on the machining side.

Methodology Applied

Scientific EffectDamping: Damping

Data Source

PatentEP4058232B1Ultrasonic component, device for machining workpieces and method for machining workpieces

Publication Date: 2026.01.21 TELSONIC HLDG AG

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AI summary

The invention relates to a sonotrode (1) for processing workpieces (W) using ultrasonic vibrations, having a sonotrode body (10). Longitudinal vibrations (SL) are introduced into the sonotrode body (10) on a sound introduction side (11) with a first end face (12). A conversion structure (15) which is used to generate transverse vibrations (ST1) from the longitudinal vibrations (SL), said transverse vibrations having a vibration component on a plane (E) perpendicular to the longitudinal axis (L), is arranged between the sound introduction side (11) and a processing side (13) opposite the sound introduction side, and a damping structure (18) which reduces the longitudinal vibrations (SL) is provided between the conversion structure (15) and the processing side (13).