Optimization design for ultrasonic horn with large amplitude based on genetic algorithm

Abstract

With the functions of amplitude amplification, impedance matching and protecting the transducer in ultrasonic machining system, ultrasonic horn is an important component in design of power ultrasonic vibration system. A new horn with large amplitude is designed. The profile of the horn is a cubic Bezier Curve. Based on genetic algorithm, the horn with large vibration amplitude ratio was obtained by optimizing the control points at the starting point and the end point of Bezier Curve. Simulation comparison was also carried out on the vibration performances of other four kinds of horns. Bezier horn and conical horn were manufactured by numerical control (NC) technology, in addition, measurement and comparison were carried out on their performances by combining with a vibrator. Results show that the amplitude of the optimized Bezier horn is 73.5 % larger than that of conical horn. Under the excitation voltage of 200 Vp-p, the amplitude of the Bezier horn can reach 108 µm