International Journal of Product Design

2015

STRATEGY OF FEM MODELING OF ULTRASONIC HORN FOR WORKPIECE

VIBRATION USED AT MICRO-ELECTRICAL DISCHARGE MACHINING
1
2

Daniel Ghiculescu1, George Seritan2, and Ovidiu Alupei3

Politehnica University of Bucharest, Romania, daniel.ghiculescu@upb.ro

Politehnica University of Bucharest, Romania, serigeorge1973@yahoo.com
3
Politehnica University of Bucharest, Romania, ovidiu.alupei@gmail.com

ABSTRACT: The paper deals with a strategy for obtaining resonance condition within an ultrasonic chain used for micro-electrical
discharge machining, based on Finite Element Method (FEM) determination of a profiled ultrasonic horn geometry needed to vibrate
a disk shape workpiece. 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 Multipysics FEM modeling of horn profile
integrating workpiece at its end. Different horn constructive elements were changed gradually to assure the control of horn natural
frequency and elongation amplification. The entry data for horn geometry determination were the dimensions and natural frequency
of transducer subassembly, which is joined with ultrasonic horn and workpiece. Based on this applied strategy, the horn integrating
the workpiece was machined by CNC, and real natural frequency obtained was very close to the result provided by FEM modeling.
KEY WORDS: Finite Element Method, ultrasonic horn, micro-electrical discharge machining.

2. PRELIMINARY DIMENSIONING OF
CYLINDRICAL STEPPED HORN

1. INTRODUCTION
Ultrasonics aiding of micro-Electrical Discharge
Machining (EDM+US) by vibrating the tool or
workpiece (in this case) proved spectacular
improvement of main technological parameters in
terms of machining rate, precision/volumetric
relative wear, and surface quality [1], [2], [3], and
new materials with low machinability [4], [5], [6].

A preliminary dimensioning was approached as a

starting point for an usual cylindrical stepped horn,
using some known relations, aiming finally at
determination of complex profiled horn, integrating
the workpiece to be vibrated during EDM+US.
The amplification (K) in case of a stepped horn, after
Merkulov and Kharitonov [9], is equal with:

But horn fabrication encounters a critical condition,

the equality between own frequency of transducer
subassembly (as entry data) and of horn which
integrates the workpiece to be vibrated resonance
condition. The considerable time consuming for this
condition achievement especially for horns complex
shape, comprising several iterative stages (horn
machining own frequency measurement) is
justified on relative great volumes of fabrication.
From this derives disagreeable lack of flexibility of
EDM+US technology. Under these conditions, the
betterment of this drawback, using FEM modeling
of ultrasonic horn, associated with Computer Aided
Machining of the horn, based on FEM results,
becomes of utmost interest nowadays when the
response of companies to client demands is critical.

K = (D1 / D2 )2

(1)

where: D1 is the entry diameter [m]; D2 is the output

diameter of the stepped horn [m]. This is applicable
when entry length (l1) and output one (l2) of the
stepped horn (upper and lower steps in figure 4)
meet the following conditions:
l1 = 1.5 /

[m]

(2)

l2 = 1.6 /

[m]

(3)

is the wave number calculated with the formula:

=2/

[m-1]

(4)

and is the wave length calculated as it follows:

=c/f

Achieving new shape (profiles in case of revolution

surfaces) of ultrasonic horn appropriate for diverse
application [7], taking into account the unique
character of horn shape in the relation to the type of
machining [8], is a very important research
direction. In case of present paper, the complex horn
integrating the workpiece positioned at its end as
antinodal point.

[m]

(5)

where f is the oscillation ultrasonic frequency. The

ultrasonics velocity (c) within a solid material is
determined with the relation:
E
c=
[m/s]
(6)

where E is Youngs modulus of horn material [Pa],

- density of horn material [kg/m3].
1

The transducer assembly provided by the Institute of

Solid Mechanics of the Romanian Academy (fig. 1)
has the own series frequency ftr= 41760 Hz of
interest for this type of applications [10], and the
output diameter of the radiant bush was =35 mm.

neck dimensions between workpiece and horn, nodal

channel radius and its vertical position, threaded
hole for workpiece and horn assembling to
transducer. After the most part of FEM stages was
done, a first variant of horn was machined,
measuring its own frequency in order to validate the
model. After step lengths adjustments, the horn was
CAM-ed, and resonance condition was fulfilled.

Reflecting bush
Supply
copper
blades

fo1, ftr, D1, D2, E,

Calculation of , , and lengths l1, l2 with
relations 2-6 at frequency fo1

PZT plates

Insert of fillet radius at main steps joint;

determination of frequency fo2 and amplification K2

Radiant bush

Insert of integrated workpiece; determination of

frequency fo3 and amplification K3
Figure 1. Transducer assembly used in ultrasonic chain for
assisted micro-EDM

Increase of workpiece radius and input fillet radius to

workpiece joint; determination of frequency fo4,
and amplification K4,

In case of our horn made from OLC 35 steel with

characteristics E=2.1 1011 Pa, = 7850 kg/m3, the
entry frequency of the horn was fo1=40.0 kHz, lower
than that of the transducer ftr. Thus, the values of
physical parameters from the relations presented
above are: =0.1293 m, =48.5674 m-1. Therefore,
the steps lengths resulted: l1=30.885 mm; l2=32.944
mm. The entry diameter of the horn, is equal with
that of radiant bush, D1=35 mm.

Insert of horn neck to workpiece joint; determination

of frequency fo5 and amplification K5
Modification of workpiece height; determination of
frequency fo6, and amplification K6,
Modification of steps lengths; determination of
frequency fo7, and amplification K7,

These above preliminary results represented entry

data for the first stage of FEM modeling.

Modification of neck height; determination of

frequency fo8, and amplification K8,

3. STRATEGY OF FEM MODELING OF

ULTRASONIC HORN WITH
INTEGRATED WORKPIECE

Insert of nodal channel for clamping; determination of

frequency fo9 and amplification K9
Modification of workpiece radius; determination of
frequency fo10, and amplification K10,

Comsol Multiphysics with Structural Mechanics

module, and Eigenfrequency submodule were used
for FEM modeling and simulation of an ultrasonic
horn, which included a disk shape workpiece at its
end, as antinodal point under conditions of standing
waves.

Modification of lower step radius; determination of

frequency fo12, and amplification K12,
Modification of nodal channel radius and its position;
determination of frequency fo11, and amplification K11,

The used strategy for modeling introduced or

changed only one constructive parameter of horn
geometry in each stage, following the control of
oscillation physical parameters, i.e. own frequency
and amplification. Consequently, in order to achieve
the needed profile of the horn, more than 20
modeling stages were covered.

No

Validation of model
by machining and measuring real horn fo
Yes

Input threaded hole for assembling workpiece and horn;

determination of frequency fo13 and amplification K13
Horn CAM with
dimensions resulted from FEM

The logical scheme depicting the modeling strategy

is presented in fig. 2. The following parameters of
horn geometry were the subject to change
successively in each modeling stage: steps lengths,
fillet radius between main steps, disk shape radius of
wokpiece at the chain end, fillet radius and horn

Modification of horn lengths

for obtaining resonance condition
Figure 2. The strategy logical scheme for FEM modeling of
the profiled stepped horn with integrated workpiece and
resonance condition obtaining

A parametric model was achieved, facilitating the

rapid changes of geometry and making the strategy
operational. The initial needed parameters were
established in Global Parameters, and presented in
fig. 3.

The corresponding FEM results for the parameters

defined in fig. 3, in terms of eigenfrequency and
deformations are presented in fig. 4.

Figure 3. The defined parameters in the first stage

Figure 5. Parameterized fillet radius of horn main steppes

The other main elements for the generic modeling

are synthesized underneath. The modeled horn
geometry was created using axis symmetric
dimensional space, based on defined parameters
from Global definitions. The needed horn material
properties were provided by Comsol Multiphysics
Materials Library and were adjusted for Romanian
OLC 45 steel used in this case. The physics
boundary conditions for horn eigenfrequency
(resonance) frequency were set on free for all
geometry limits. The mesh was set on extrafine, with
more than 2300 elements for final models and
average quality around 0.96 on a 0-1 scale.

Consequently, the corresponding FEM results are

presented in fig. 6. It can be noticed that fillet radius
insertion produced increase of horn natural
frequency and amplification, i.e. the ration between
displacements at the two ends of the horn 1 is
considered at superior (entry) surface of the horn.

In the next stage, a new parameter was introduced in

Global Parameters model as fillet radius between
main steps, as it is presented in fig. 5.

4. ANALYSIS OF FEM RESULTS AND

ULTRASONIC HORN ACHIEVEMENT

The analysis of the most important results obtained

by FEM modeling, and the geometrical parameters
of horn construction are presented below.

Entry step
(r1, l1)
Figure 6. Resonance frequency and displacements at insertion
of fillet radius between horn main steps

The new parameters needed for workpiece insertion

by modification of horn shape end are presented in
fig. 7.

Output step
(r2, l2)

Figure 7. Parameters introduced for workpiece and its fillet

radius modeling

The results obtained in terms of resonance frequency

and displacements with parameters values presented
above are shown in fig. 8.

Figure 4. Resonance frequency and displacements at

initial stage

The next stage was focused on the nodal channel

insertion needed to clamp the ultrasonic chain on
electrical discharge machine. A nodal level was
determined (minimum oscillation amplitude) as it is
shown in fig. 11.

Figure 8. Resonance frequency and displacements at insertion

of workpiece and its fillet radius

A decrease of horn resonance frequency and of the

amplification was perceptible in this stage in
comparison with the previous one.
The parameters needed to insert the neck between
the workpiece and the rest of the horn, having the
goal of stiffness increase, are presented in fig. 9.

Figure 11. Nodal level determination

At this level, a radial channel was introduced, which

serves at horn clamping by four pointed radial
screws, which enter this channel.
The parameters needed to model this nodal channel
are presented in fig. 12.

Figure 9. Parameters introduced for neck modeling

In fig. 10, the resonance frequency obtained in this

stage and the corresponding displacements of the
horn are presented. Therefore, a slight decrease of
horn own frequency and amplification was produced
in comparison with previous shape.

Figure 12. Parameters needed to insert nodal channel

The own frequency and displacements obtained by

nodal channel insertion were presented in fig. 13.

Figure 13. Resonance frequency and deformations at nodal

channel insertion

Figure 10. Resonance frequency and displacements at insertion

of neck between horn and workpiece

A decrease of horn natural frequency was produced

by the nodal channel insertion, amplification being
slightly increased.
In order to extend the diameters range of the
workpieces to be machined by EDM+US, the
radius of workpiece was increased gradually. In this
stage, the value of this parameter is specified in fig.
14.

Figure 14. Current value assigned to workpiece radius

The natural frequency and displacements

corresponding to this stage were presented in fig. 15.
Thus, the workpiece radius increase determined
resonance frequency decrease and amplification
increase.

Figure 17. Resonance frequency and displacements at

adjustment of channel radius, lower step radius, neck height,
and workpiece radius

After horn CAM based on FEM results, measuring

the resonance frequency of ultrasonic horn and chain
assembly was done, under working conditions cavitation in the liquid in which the workpiece is
immersed - as it is presented in fig. 18. This was
needed to validate the model before machining the
final shape of the horn. This setup is also necessary
for the accordance of the ultrasonic generator on
nominal frequency of around 40 kHz, its adaptive
control working within 1kHz range.
Support
Versatester

Figure 15. Resonance frequency and displacements at increase

of workpiece radius

Tektronix
oscilloscope

Transducer
subassembly

The parameters modified in the following stages are

presented in fig. 16, and horn natural frequency and
displacements were presented in figure 17.
Ultrasonic
horn
Integrated
workpiece
immersed in
liquid

Figure 16. Values assigned to parameters

Figure 18. Measuring stand for natural frequency of ultrasonic

horn and chain used at assisted EDM and generator accordance

The above values of the parameters led to increase

of natural frequency and of amplification. Through
increase of own horn frequency, it is aimed at
obtaining the resonance condition, i.e. equality
between the one of horn and transducer, which is
higher.

A good agreement was achieved between FEM

modeling and measured natural frequency, less than
1%. On this basis, the final horn model was created,
including longitudinal threaded holes (M6 and M12)
5

for workpiece assembling and junction with

transducer, represented in fig. 19.

6. ACKNOWLEDGEMENT

The presented results are obtained in Joint Applied

Research Project, C4, 222/2014.
7. REFERENCES
1. C. Gao, A. Liu, Study of ultrasonically aided of
micro-electrical-discharge-machining by the
application of workpiece vibration, J. of Mat.
Process. Technology Vol. 139, pp.226228,
(2003).
2. M. R. Shabgard, B. Sadizadeh, H. Kakoulvand,
The Effect of Ultrasonic Vibration of Workpice
in Electrical Discharge Machining of AISIH13
Tool Steel, World Academy of Science,
Engineering and Technology, Vol 3. pp. 332336, (2009).
3. J.-C. Hung, et al., Using a helical micro-tool in
micro-EDM combined with ultrasonic vibration
for micro-hole machining, J. Micromech.
Microeng., Vol. 16, pp. 2705-2713, (2006).
4. H. Huang, et al., Ultrasonic vibration assisted
electro-discharge machining of microholes in
Nitinol, J. Micromech. Microeng., Vol. 13 pp.
693-700, (2003).
5. Kiyoshi Suzuki, Takuya Takada, Zhi Rong
Zhou, Takuya Okamichi, Manabu Iwai, Shinichi
Ninomiya, Effects of Ultrasonic Vibrations
Given to an Electrode on the EDM Performance
in Processing PCD, Advanced Materials
Research, Vol. 565, pp. 394-399, (2012).
6. B.H. Yan, et al., Study of precision micro-holes
in borosilicate glass using micro EDM combined
with micro ultrasonic vibration machining,
International Journal of Machine Tools &
Manufacture, Vol. 42, pp. 11051112, (2002).
7. I. Duds, A. Kyusojin, Gy. Varga, H. Isobe, Cs
Oravecz,
Experimental
Examination
of
Propagation of Longitudinal Deformation of
Different Shapes of Horn Used at Ultrasonic
Machining, 11th Int.Conf. on Tools, Univ. of
Miskolc, pp. 317-324, 09-11, (2004).
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Applied
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machining
technologies,
Computational Mechanics, Vol 4., pp. 7988,
(2010).
9. V.K. Astashev, V. I. Babitsky, Ultrasonic
Processes and Machines: Dynamics, Control
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10. I. Getman, S. Lopatin, Matching of series and
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Figure 19. Final modeling of ultrasonic horn

The horn was obtained by CAM, and the workpiece

was detached from the horn by WEDM, being later
assembled with the horn. Using these constructive
solutions, the resonance condition was achieved,
existing a reserve of horn lengths that can be used
for shorten them to get the target of ftr= 41760 Hz.
5. CONCLUSIONS

The influence of some constructive elements of

ultrasonic horn was identified based on FEM
modeling strategy: fillet radii are able to increase the
natural frequency and its amplification, against other
elements like radii extension of disk shapes inserted
in horn construction, which produced decrease of
natural frequencies and its amplification. The same
influence was observed in case of radial channels
insertion, but their profile radius diminishing can
increase the horn natural frequency.
FEM modeling strategy led to ultrasonic horn
complex shape achievement integrating disk shape
wokpiece at its end as antinodal point. Thus, a good
agreement was obtained between real horn natural
frequency and that provided by FEM, less than 1%,
this facilitating the resonance condition achieving
for an ultrasonic chain used at EDM+US.
The presented modeling strategy was able to
significantly decrease machining preparation time
needed for ultrasonic assistance of EDM, thus
contributing to increase its flexibility, considered as
its main drawback for industrial applications.
6