Preliminary Results for Optimal Design of the Horn with Complex Welding Profiles in Ultrasonic Welding

In the ultrasonic welding system, the horn is a very important part, its working mode determines the quality of the weld. It is for this reason that the horn design is constantly being improved by researchers to increase productivity. There have been design studies on welding horns with different profiles, but with complex welding profile, such as the profile of welding turn signals on cars, there have been few studies published. In this paper, the design and simulation of welding horns with complex welding profiles used in auto-turn signal welding will be presented. There are two design steps that are of interest, the initial design, without the slots, and the advanced design – with the slots. The results show that the performance of the advanced design is better than that of the initial design at three criteria such as amplitude uniformity, small stress generation, and resonance frequency separation. The research results in this paper open up a development direction to study complex welding profiles for industrial use.