Finite element modeling of an ultrasonic horn integrating the tool for

micro-electrical discharge machining

GHICULESCU Daniel1, a, MARINESCU Niculae-Ion1,b, KLEPKA Tomasz2,c
and ALUPEI-COJOCARIU Ovidiu-Dorin1,d
1

Politehnica University of Bucharest, Romania,

2

Lublin University of Technology, Poland.

daniel.ghiculescu@upb.ro, bniculae.marinescu@yahoo.com, ct.klepka@pollub.pl

d

ovidiu.alupei@gmail.com

Keywords: ultrasonic, horn, micro-electrical discharge machining, finite element modeling.

Abstract. The paper deals with a strategy to obtain a complex conical ultrasonic horn, which
integrates the tool for micro-drilling through electrical discharge machining (EDM+US) based on
Finite Element Method (FEM) modeling. This approach comprises more than 20 stages, starting
with preliminary determination of a basic profile stepped horn through mathematical relations. The
next stages are based on Comsol Multiphysics FEM modeling, changing gradually different horn
constructive elements and integrating the tool and their clamping parts. The entry data for horn
geometry determination were the dimensions and own frequency of transducer subassembly,
joining ultrasonic horn. Finally, the CAD file of horn was transferred to CAM file and CNC
machined. Horn real own frequency obtained was very close to the result provided by FEM
modeling.
Introduction
Ultrasonics aiding of micro-Electrical Discharge Machining (EDM+US) by vibrating the tools
(in this case) or workpiece proved advances in surface quality, precision/volumetric relative wear,
and machining rate [1], [2], [3], also in case of new materials with low machinability [4], [5], [6].
Nevertheless obtaining the sine qua non conditions of resonance - equality between assemblies
of transducer (fotr) and ultrasonic horn (foh) - mainly in case of complex shape ultrasonic horn, is an
intricate and time consuming process, containing several iterative stages (horn dimensional
adjustment own frequency measurement). This is a technologic task, justified on relative great
volumes of fabrication, and consequently showing lack of flexibility of EDM+US technology. But
FEM modeling of ultrasonic chains facilitates the resonance condition obtaining. In this case a
conic shape horn - leading to low cost manufacturing mainly by conventional machining against
other complicate curve profiles - that integrates the tool for micro-holes is approached.
Coupling FEM with Computer Aided Machining (CAM) of the horn becomes of utmost interest
nowadays, new shapes of ultrasonic horn appropriate for diverse application being achieved [7],
taking into account the unique character of horn shape in relation to type of machining [8].
Preliminary Dimensioning of an Usual Cylindrical Stepped Horn
A preliminary dimensioning was carried on for usual cylindrical stepped horn, standing as entry
data for FEM modelling of complex profiled horn, integrating the tool to be axially vibrated during
micro-drilling by EDM+US. Some known relations were used. The upper (l1) and lower (l2) steps
lengths in case of a cylindrical horn (see Fig. 4), after Merkulov and Kharitonov [9], are equal with:
l1 = 1.5 /

[m],

(1)

l2 = 1.6 /

[m],

(2)

where is the wave number calculated with relation:

[m-1],

=2/

(3)

and is the wave length calculated as it follows:

=

c 1
=
f
f

[m],

(4)

where f is the oscillation ultrasonic frequency [Hz]; c - ultrasound velocity within a solid material
[m/s]; E - Youngs modulus of horn material [Pa], - density of horn material [kg/m3].
The previous dimensional conditions lead to amplification (K), which is equal with:

D
K = 1
D2

(5)

where: D1, D2 are the entry diameter, and the output diameter of the stepped horn [m] - see Fig. 4.
The transducer assembly provided by the Institute of Solid
supply
reflecting
Mechanics of the Romanian Academy - IMSAR (Fig. 1) has
and
bush
cooling
the own series frequency fotr= 40805 Hz entry data for this
flange
application type [10]. Its radiant bush, which joints the
concentrator, has output diameter Db=35 mm. In case of our
PZT
horn made from Romanian OLC 35 steel, the needed
rings
characteristics are: E=2.1x1011 Pa, = 7850 kg/m3. Its entry
frequency for calculation was fo1=40.0 kHz, lower than that of
radiant
the transducer fotr. Therefore, values of physical parameters
bush
from the above relations are: =0.1293 m, =48.5674 m-1.
So, resulted steps lengths are: l1=30.885 mm; l2=32.944 mm. Fig. 1. 40 kHz Transducer - IMSAR
The horn entry diameter is D1= Db=35 mm.
Strategy Based on Finite Element Method

Using FEM modeling strategy, only one constructive parameter of horn geometry was
introduced or changed in each stage, aiming at control of own frequency foi and amplification Ki,
and thus having a permanent feed-back. Therefore, more than 20
ftr,fo1, E, , D1, D2
modeling stages of strategy were covered, whose generic
logical scheme is presented in Fig. 2.
Calculation of , , and lengths l1, l2
Comsol Multiphysics with Structural Mechanics
with relations 1-4 at frequency fo1
module, and Eigenfrequency submodule were used for
Insert, modification of filet radius
FEM modeling and simulation of a complex ultrasonic
Insert, modification of taper angle
horn, which included tool and its clamping at horn end Insert, modification of threaded hole
Insert, modification of nodal channel
antinodal point under conditions of standing waves.
Insert, modification of tool and clamping
The needed material properties were provided by
Modification of l1, l2
Comsol Library and were adjusted for real (measured
Determination of foi and Ki
sound velocity) OLC 45 steel used for horn and real
copper 99.5 for tool. The physics boundary conditions for
No
Validation of model by foi
Yes
horn eigenfrequency were set on free for all geometry
Horn CAM adjusting l1, l2 for resonance condition
limits. The modeled horn geometry was created using 2D
Fig. 2. Logical scheme of FEM modeling
axis symmetric space, using defined parameters like those
strategy
applied to complex horn with tool
presented in Fig. 3 for the first stage.

Other parameters introduced during

modeling strategy will be presented below in
correspondence with results analysis.
The mesh was set on extrafine, with more
than 2000 elements for final models and
average quality around 0.96 on 0-1 scale.

Fig. 3. Defined parameters for initial stage

Results Analysis

l1

D1

l2

The analysis of the results obtained in most

important stages of FEM modeling of complex conical
horn, and their related geometrical parameters are
presented in this section. In the initial stage, the horn
own frequency and its amplification (in direct relation
with relative displacements) are presented in Fig. 4 in
correspondence with parameters previously defined
(Fig. 3).
In the next stages, the taper angle (alpha) was
introduced at lower step of the horn and the needed
parameters for geometry construction are presented in
Fig. 5.

D2

Fig. 5. Parameters at taper insertion at lower horn step

Fig. 4. Own frequency and displacements at

initial stage

In comparison with usual horn from initial stage, the amplification increased, i.e. the ratio
between relative displacements at two ends of horn (value 1 is considered at entry (superior) surface
of the horn), and the own frequency of conical shape horn also increased as it is presented in Fig. 6,
7. At taper angle increase, as it can be noticed, the horn own frequency also increased gradually.

Fig. 6. Own frequency and displacements at 1o taper angle

Fig. 7. Own frequency and displacements at 5o taper angle

In the subsequent stages, the tool

was inserted and its clamping parts
from the same material with the
horn. It is considered that these
parts make perfect contact with the
conical hole for assembly machined
Fig. 8. Parameters needed for tool insertion
within the horn. This determines no
modification of corresponding own frequency of horn assembly as previous running of programmed
model pointed out. The dimensions of remained cavity unfilled by clamping parts were
parameterized as well as tool dimensions, and presented in Fig. 8.

Fig. 9. Own frequency and displacements at tool insertion

and clamping parts

Fig. 10. Own frequency and displacements at tool

insertion and clamping parts with 6o taper angle of lower
step

As one can notice, insertion of tool and its clamping system determined decrease of horn
assembly own frequency together with amplification in comparison with previous model (Fig. 9).
Increase of taper angle at 6 is able to compensate some reduction of foi and Ki values (Fig. 10).
In the next stages, a preliminary determination of a nodal point was carried on in order to create
a nodal channel for clamping the ultrasonic chain assembly. A limited range of amplification, in
terms of visualization of colored zone, led to coordinate z = 39.3 mm for nodal point (see Fig. 12).
This was followed by insertion of
radial nodal channel in horizontal plane,
comprising nodal point with coordinate z,
mentioned above. The defined parameters
for nodal channel construction are
Fig. 11. Parameters for nodal channel insertion
presented in Fig. 11.
As it can be noticed, from Fig. 13, the insertion of nodal channel determined a decreased of own
frequency and amplification as well, in comparison with previous model.

Fig. 12. Preliminary determination of nodal point

with z coordinate of 39.3 mm

Fig. 13. Own frequency and displacements at insertion of

nodal channel

In the following stages the hole threaded and stud

were inserted, which are used to assembly the
transducer with the horn at its upper end, with the
parameters for modeling presented in Fig. 14. These
constructive changes produced own frequency and Fig. 14. Parameters for threaded stud and hole
amplification decrease, as Fig. 15 pointed out.
In the final stages, for resonance condition reaching, the step lengths (l1 and l2) were increased;
von Mises stress was decreased in the zone of pointed inner surfaces (as previous running models
indicated) through their radii increase; the position of nodal channel was changed to correct the
displacement of nodal point produced by previous constructive changes ( Fig. 16).

Fig. 15. Own frequency and displacements at threaded

hole and stud insertion

Fig. 16. Corrections needed to reach resonance condition

and proper horn working

The strategy of complex horn was finalized through machining by CAM of its final version
resulted from FEM, whose real own frequency proved to be very close under entry frequency fotr=
40805 Hz. Only fine adjustments of step lengths by their reduction were executed for resonance.
Conclusions

A strategy for ultrasonic complex horn achievement that integrated the tool and its clamping
parts was completed based on FEM modeling and horn CAM in order to ease the ultrasonic chain
resonance obtaining. FEM results indicated that positioning of clamping elements at horn end in
antinodal point led to proper working of ultrasonic chain - the tool appropriate for micro-drilling
through EDM exerted very low influence on own frequency of horn assembly. Other constructive
elements of complex conical shape horn, introduced step by step, like filled radius between exterior
surfaces, taper angle, cavities and threaded holes increased horn own frequency. Other elements
like nodal channel, tool and threaded stud insertion decreased horn frequency. Such CAE-CAM
approached strategy proved its capacity to improve flexibility of EDM+US technology.
Acknowledgement

The paper was achieved in Joint Applied Research Project supported by MEN-UEFISCDI,
project no. PN-II-PT-PCCA-2013-4-0236, Contract no. 222/2014.
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