Abstract—The Ultrasonic Welding (USW) process is mainly based on the design of the horn to ensure that it vibrates in the longitudinal position to achieve a proper welding process, and the best design of the horn is based on obtaining the largest possible amplitude during the longitudinal vibration. In the current study, the model and harmonic analysis were performed using the ANSYS/r21 program according to the response surface methodology matrix obtained from the software program, the design was optimized using the visual basic program, and the best horn design was found to provide the largest possible vibration amplitude. The findings demonstrate that the sonotrode can reach a maximum amplitude of 52.345 microns. And, the sonotrode’s output face exhibits the highest longitudinal wave separation of 83.3% and the best uniformity of displacement amplitude when it comes to welding.

Keywords—ultrasonic welding, catenoid sonotrode modal analysis, harmonic analysis, design optimization, response surface methodology

Cite: Abdulhaqq A. Hamid and Mohammed Najeeb Abdullah, "Optimal Design of Catenoidal Sonotrode for Ultrasonic Welding Process," International Journal of Mechanical Engineering and Robotics Research, Vol. 13, No. 3, pp. 402-407, 2024.

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