Ultrasonic Welding Molding horns

Sonotrode, also known as the horn or sonotrode in an ultrasonic welding system, is a critical component that 

amplifies and focuses the high-frequency vibrations generated by the transducer to the welding area. Here's a 

detailed explanation in English:

Basic Definition

The sonotrode is essentially the business end of the ultrasonic welding system, responsible for transferring the

vibrational energy to the materials being welded.

Sonotrode Examples 

All mold plates are customization to meet different products design and accuracy.

 Samples and 3D drawing are required for making horn and bottom mold accordingly.

Finite element analysis (FEA)

Horn design is a complex process that requires careful consideration. 

The right material must be chosen, the horns need to be balanced, and

they must be designed to achieve the desired amplitude while being 

precisely tuned to a specific frequency. Poorly tuned horns can potentially 

damage the converter or power supply. Tooling Engineers utilize

 Finite Element Analysis (FEA) to design and optimize horns,

 ensuring they are properly tuned, maintain appropriate stress levels, 

meet amplitude requirements, and provide uniform performance.

Working Principle

Mechanical Vibration Transfer: The sonotrode amplifies the vibrations produced by the piezoelectric 

transducer and evenly distributes them to the welding area. This creates frictional heat at the interface of 

the materials, facilitating their fusion.

Precision Control:The design and manufacturing of the sonotrode often involve FEM (Finite Element Method)

calculations to ensure optimal oscillatory behavior. Advanced laser measurement techniques are used to 

measure and record amplitude distribution, ensuring precision during the welding process.

Applications

Sonotrodes are widely used in various fields, particularly in the automotive industry for battery assembly 

connections, tab welding, fuse welding, and more. They can weld similar and dissimilar metals, metal to 

non-metal, plastics, and materials with significant thickness differences.

Performance Characteristics

High Precision: CAD/CAM calculated algorithms ensure precise 3D contour manufacturing for high-precision 

welding needs.

Longevity: Special surface treatment processes extend the lifespan of the sonotrode.

Efficiency and Energy Saving: Ultrasonic welding does not require external heating sources, consumes less

electrical energy, and offers fast welding speeds, enhancing production efficiency.

Technical Advantages

Broad Material Compatibility: Capable of welding various types of materials, including highly conductive, 

thermally conductive materials, and difficult-to-weld metals.

High-Quality Weld Joints: The physical and mechanical properties of the weld metal remain unchanged, 

providing stronger and more stable joints compared to resistance welding.

Environmentally Friendly: No need for adhesives, fillers, or solvents, making the process environmentally 

friendly and free from contamination.

In summary, the sonotrode is a crucial tool in ultrasonic welding systems, playing a vital role across multiple

 industries. As technology advances, the performance and application scope of sonotrodes continue to expand.

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