Design an Ultrasonic Cutting Horn for Robotic Thermoplastic Trimming Applications

Abstract

This research presents the design and development of an ultrasonic cutting horn integrated with a robotic system for trimming Thermoplastic materials in automotive applications. The horn was designed using titanium alloy (Ti6Al4V) to achieve optimal mechanical strength, low mass, and superior acoustic properties. Finite Element Analysis (FEA) was conducted to ensure that the horn operated at the targeted frequency, resulting in a simulated resonance of 28.87 kHz. Experimental testing confirmed an actual operating frequency of 28.44 kHz, with a deviation of only 1.5%, indicating high model accuracy. The horn-blade assembly was mounted on an industrial robot for cutting trials, demonstrating smooth cut surfaces, clean edges, and reduced cutting resistance compared to conventional non-ultrasonic cutting. The results validate the feasibility and advantages of using ultrasonic energy for robotic TPO trimming, enabling precise, efficient, and high-quality cutting performance suitable for automotive manufacturing processes.