Design and Analysis of Acoustic Horn for Assistance in Die-Sinking EDM

Many industrial applications and production technologies are based on the application of ultrasound. In many cases, the phenomenon of ultrasound is also applied in the technological processing of the machining of materials. The main element of equipment that uses the effect of ultrasound for machining is the ultrasonic horn. It is also called a sonotrode. The performance of ultrasonic machining technologies depends on the properly designed sonotrode shape. The dependence of fundamental modal properties (natural frequencies, mode shapes) of various sonotrode shapes for various geometrical parameters is analyzed. Modal analysis of the models is determined by the numerical simulation using the finite element method (FEM) design procedure. In ultrasonic machining, the ultrasonic horn plays a vital part in the high-energy machining process. Electric discharge machining (EDM) is used to achieve high processing quality but the machining efficiency is low. The new (EDM+USM) is used for high machining efficiency. The acoustic analysis of the ultrasonically vibrating tool is done with the assistance of the finite element method (FEM) so that it can be used for EDM applications.