Design an Ultrasonic Cutting Horn for Robotic Thermoplastic Trimming Applications

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.The