Design and finite element analysis of longitudinal vibrating stepped ultrasonic horn

In this paper, a longitudinal vibration stepped ultrasonic horn was designed, and the size parameters of the ultrasonic horn were designed by theoretical calculation. In order to verify the rationality of the ultrasonic horn design, the finite element analysis software was used to perform a modal analysis on the horn, and the vibration mode and natural frequency of the ultrasonic horn within the design frequency range were obtained. The modal analysis results show that the natural frequency of the longitudinal vibration of the horn had a large error from the design frequency. Therefore, the size of the horn was optimized to make the natural frequency of the ultrasonic horn conform to the design frequency requirements. In addition, the optimized ultrasonic horn reduces the maximum stress which improves the safety and service life of the horn.