Abstract—In this study, three-dimensional FE modal analyses were conducted to examine the Sonotrode’s vibration characteristics. Since the excitation frequency was 20 kHz, the frequency range was set between 15 and 35 kHz. The density and elastic modulus of the Sonotrode material, AL7075, were 2802 kg/m³ and 71.9 GPa, respectively. Finite Element (FE) modal analyses were conducted using ANSYSTM. Because of the AL7075's good mechanical properties and excellent ultrasonic transmission capabilities represented by high amplitude; it was utilized. A quadratic mathematical model of the displacement amplitude based on the dimensions was developed using the response surface methodology. When compared to the Response Surface Model (RSM) results, the study's conclusions demonstrated that the ideal Sonotrode, which yields the highest value for the performance input, could be found using the recommended RSM-GA integration technique. The ideal entrance dimensions are then ascertained by combining the RSM model with GA. The ideal results showed that the highest vibration amplitude is 57 microns, and it was also found that the variables X2 and X4 do not affect the vibration amplitude.

Keywords—ultrasonic welding, stepped Sonotrode, plastic welding, harmonic response, optimal design, response surface

Cite: A. D. Younis, Ziad. S. Al Sarraf, Abdulhaqq A. Hamid, and Zaid T. ALdabbagh, "Optimal Multi-stepped Sonotrode Design for Ultrasonic Plastic Welding," International Journal of Mechanical Engineering and Robotics Research, Vol. 14, No. 3, pp. 238-244, 2025. doi: 10.18178/ijmerr.14.3.238-244

Copyright © 2025 by the authors. This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited (CC BY 4.0).