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How to design and produce ultrasonic molds?

发布者:灵科超声波 发布时间:2018/10/9

How to design and produce ultrasonic molds?


Many people think that ultrasonic molds and production are very simple things, because they mistakenly think that the mold is not too technical, and a single mold with good shape can be produced and welded. Now I can tell you seriously that this is a very wrong idea and should not be easily misled in the future. Because if a welding head is not tuned (adjusted frequency) and a machining is not used, it will affect the entire welding effect, and some will damage the transducer or generator, so that production will become huge. Loss.


Ultrasonic molds are a part of the need for technical depth. Only after strict standards and repeated tests can we produce high-quality welding heads, which makes the matching of the welding head and the mold more perfect, thus achieving perfect welding.


There are a few points about the mold, we can first understand:


1. Mold frequency parameters, any ultrasonic welding machine has a center frequency, which is generally determined by the mechanical resonance frequency of the transducer, horn and welding head. The frequency of the generator is adjusted according to the mechanical resonance frequency. To achieve agreement and keep the horn working in resonance, each part is designed as a half-wavelength resonator.




Each of the welding heads will adjust the resonant frequency, and the error between the resonant frequency and the design frequency is required to be less than 0.1kHz.


2. Amplitude parameter of the mold: The amplitude of the material to be welded is a key parameter. If the temperature is too high, the raw material will burn or even cause structural damage, and the strength will be deteriorated. If the temperature is not reached, the plastic cannot be melted, which means that the welding is not possible. The amplitude of the transducer output is not the same. After adapting the variator and the welding head with different ratios, the working amplitude of the welding head can be corrected to meet the requirements. The ratio of the horn and the horn is the same as the horn. And the shape of the welding head, the front-to-back area ratio and other factors, the shape is similar to: exponential amplitude, functional amplitude, step-type amplitude, etc., have a great influence on the ratio, the ratio of the front and back area to the total ratio Just proportional. When using different brands of ultrasonic welding machines, the drunk is made according to the proportion of the working welding head, which is simple and can guarantee the stability of the amplitude parameters.


3. Processing precision of the welding head Because it works under high frequency vibration, it is necessary to maintain a symmetrical design to avoid unbalanced stress and lateral vibration caused by the asymmetry of sound wave transmission. Unbalanced vibration can cause heat and break of the welding hair. . When applying ultrasonic welding in different industries, the precision of processing is also different. For example, lithium-ion batteries and gold foils have high processing precision. Random ultrasonic welding manufacturers use numerical control equipment as processing equipment to ensure the precision of processing. Meet the requirements of.


4. Vibrating node welding head and horn: Both are designed as a half-wavelength resonator with an operating frequency. Under the working condition, the amplitude of the two end faces is drunk, the stress is drunk, and the amplitude of the node corresponding to the intermediate position is Zero, stress is drunk. The position of the node is generally designed to be a fixed position, but the usual fixed position is designed to have a thickness greater than 3 mm, or the groove is fixed, so the fixed position does not necessarily have a zero amplitude, which causes some sound and part of the energy loss. The sound is usually isolated from other components by a rubber ring or shielded with a sound insulating material. Energy loss is taken into account when designing the amplitude parameters.


The main points of the welding head and the mold are the above points, and the other factors that affect the mold are also mentioned by the way. We all know that the mold has a life span, which is the service life.


The first is the material of the welding head, aluminum-magnesium alloy:


1.2024T651: It is generally used in the manufacture of HORN. It has good enthalpy properties, strong thermal conductivity and moderate hardness. It is used in general plastic products.


2.6061T651: Used in HORN with lower output, good flexibility and soft quality


3.7075T651: Used in vibration system and Horn manufacturing, this material has high mechanical yield strength, high hardness and strong ultrasonic thermal conductivity. It is an ideal ultrasonic mold manufacturing material.


The second is titanium alloy: it is used for continuous vibration, with high toughness, good heat conduction and high hardness, but the price is relatively expensive.


The third type is hard aluminum alloy, domestically produced materials, which are mostly used for ordinary aluminum processing, with low heat conduction and low price, but the ultrasonic mechanical loss will be relatively high.


In addition, in terms of process materials, ultrasonic welding requires good flexibility of the metal material, so that the mechanical loss during the sound wave transmission process is also reduced. Therefore, aluminum alloy or titanium alloy is generally used.


The life of an ultrasonic mold is highly dependent on the material, which is also a key reason for the effectiveness of the welding product.


See here, I believe everyone knows the importance of the welding head and the mold. If you need to produce the mold welding head, you must first understand the quality requirements and precision requirements you need to avoid unnecessary losses in subsequent production. . If you need it, please contact us!


There is more knowledge about ultrasonic welding waiting for you. If you have any questions, please visit our Lingke Ultrasound, we will update the knowledge of plastic welding regularly, and there will be more ultrasonic welding machines in the future. Dry goods!


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