ABSTRACT
A plastic element is produced using the injection molding technique. Various methods are available to detach the barrel from the gates, such as cutting with a blade, hot wire, or laser. However, these methods generate heat and take more time to complete. In contrast, ultrasonic machining can break off the barrel without producing heat and with minimal machining time. This research aims to create an ultrasonic horn that produces longitudinal vibrations at an optimized frequency while maintaining low-stress concentration in finite element analysis (FEA). The optimized design is compared with the SJ-26a ultrasonic machine horn, and it shows lower stresses, directional deformation, and total deformation. The maximum principal stress was reduced almost four times compared to the old design, from 0.44 MPA to 0.12 MPA. Upon fine-tuning the ultrasonic horn in the machine, the research successfully attained a vibration duration of 0.29 seconds and a rest duration of 0.48 seconds on the workpiece. The total machining time for a single pass is 1.25 seconds. By utilizing tuning parameters, our ultrasonic horn effectively detached all plastic elements from the gates of the workpiece within one cycle.
