The transmission ratioDepending on the design, the sonotrode has its own transmission ratio resulting from its geometry. This describes the ratio between the amplitude at the base point and the amplitude at the cutting or welding contour. In many cases, the transmission ratio within the sonotrode cannot be made sufficiently large, either because the diameters become too large or because the cross-sectional jump would lead to overloading of the material. In these cases, the amplitude can be increased using external boosters.
How is a sonotrode created?
Before a sonotrode can be manufactured, the designer defines the contours based on the component geometry. Depending on the size of the workpiece and the material, the frequency is then selected and a CAD model is created using reference data. The finite element method (FEM) is then used to adjust the vibration behavior. This means that the model is modified until the vibration behavior is optimal in terms of both amplitude and uniformity. The CAM data for the machining center is then generated from the CAD model and the sonotrode is manufactured by machining the solid material.
Fault patterns and countermeasures
Sonotrodes are subject to wear due to material contact as well as thermal and mechanical loads. We have summarised some typical error patterns in this video.
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