New methodology for the design of advanced ultrasonic transducers for welding devices

A new high frequency ultrasonic transducer has been conceived, designed, prototyped and tested. The transducer is made of titanium and vibrates at the resonance frequency of 125 kHz. In the design phase an advanced approach was used and established. The method is based on an initial draft obtained with Finite-Elements-Method simulations (FEM). The simulated ultrasonic converters and resonators are then built and characterized experimentally through laser interferometry measurements and electrical resonance spectra. The comparison of simulation results with experimental data allows the parameters of FEM models, such as material constants or friction coefficients to be adjusted and optimised. The new transducer is fixed on the Wire Bonder with a flange whose special geometry was calculated by means of FEM simulations.