1583.

Optimization design for ultrasonic horn with large

amplitude based on genetic algorithm
Tao He1, Xin-Quan Ye2, Yang Zhao3
1, 2Collegeof Oujiang of Wenzhou University and College of Mechanical and Electrical Engineering of
Wenzhou University, Wenzhou, 325035, China
3Electronic and Information Technology Department, Jiangmen Polytechnic, Jiangmen 529090, China
3Corresponding author

E-mail: [email protected], [email protected], [email protected]

(Received 1 October 2014; received in revised form 21 November 2014; accepted 20 December 2014)

Abstract. With the functions of amplitude amplification, impedance matching and protecting the
transducer in ultrasonic machining system, ultrasonic horn is an important component in design
of power ultrasonic vibration system. A new horn with large amplitude is designed. The profile of
the horn is a cubic Bezier Curve. Based on genetic algorithm, the horn with large vibration
amplitude ratio was obtained by optimizing the control points at the starting point and the end
point of Bezier Curve. Simulation comparison was also carried out on the vibration performances
of other four kinds of horns. Bezier horn and conical horn were manufactured by numerical control
(NC) technology, in addition, measurement and comparison were carried out on their
performances by combining with a vibrator. Results show that the amplitude of the optimized
Bezier horn is 73.5 % larger than that of conical horn. Under the excitation voltage of 200 ,
the amplitude of the Bezier horn can reach 108 µm.
Keywords: ultrasonic horn, vibration amplitude ratio, genetic algorithm, Bezier Curve.

1. Introduction

With the functions of amplitude amplification, impedance matching and protecting the
transducer in ultrasonic machining system, ultrasonic horn is an important component in design
of power ultrasonic vibration system [1]. Horn with large amplitude are increasingly widely
applied in various ultrasonic applications, such as ultrasonic operation [2], ultrasonic motor [3],
ultrasonic wave lubrication [4] and ultrasonic welding [5] etc. According to different shapes of
horn, the ultrasonic horns can be divided into stepped [6], exponential [7], conical [8], catenary
[9] and constant stress [10] etc. Salmon [11] et al. designed an exponential horn by exponential
function. They pointed out that the horns whose profiles were not straight lines often had higher
amplitude compared with traditional horns.
Commonly used horns mainly include stepped-shaped, conical, exponential and
Gaussian-shaped [12] horns. Abromov [12] pointed out that under the same shape factors, the
amplitude amplification coefficient of a conical horn is larger than that of an exponential horn and
less than that of a stepped-shaped horn. Although stepped-shaped horn has large amplification
coefficient of amplitude, it is prone to fracturing as it has larger stress due to its mutated
cross-sectional area. Therefore, it’s not applicable to ultrasonic applications with large amplitude
[10]. Horns with constant stress [10] have both comparatively large amplitude and small stress.
Theoretically, the amplitude of horns with equal stress is larger than that of stepped-shaped horn.
However, horns with constant stress are more complicated and are expensive in terms of both
design and processing. Table 1 shows the comparison of advantages and disadvantages of
commonly used horns. New design methods are required in order to design horns with both large
amplitude and small stress.
Common design methods for horns include analytical method [1], equivalent circuit method
[13] and equal mechanical impedance [14], transfer matrix method [15] and finite element method
[16]. Various parameters of the horns can be obtained by traditional analytical methods subject to
complicated calculation [17]. With the development of computer technology and the perfection of
finite element theory, making use of finite element can not only accurately calculate the various

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 1583. OPTIMIZATION DESIGN FOR ULTRASONIC HORN WITH LARGE AMPLITUDE BASED ON GENETIC ALGORITHM.
TAO HE, XIN-QUAN YE, YANG ZHAO

parameters of complicated shaped horns, but also simplifies the calculation process significantly.
Designing horns by means of parameterization curve and finite element technology is a new design
method [18]. Large amplitude ratio can be acquired and it’s easy to process. Parameterization
curve can flexibly adjust the cross-section shape of the horns by adjusting various parameters,
thus obtaining the horns with required amplitude ratio and frequency.
In this paper, a new ultrasonic horn with large amplitude is designed based on Bezier
parameterized curve. The profile of the horn is a cubic Bezier Curve. The horn with the maximum
amplitude ratio under certain frequency was acquired by multi-objective optimization design
genetic algorithm. The vibration state of the horn was analyzed by means of ANSYS finite element.
The curve of detailed stress and displacement distribution were obtained. The horn was
manufactured by means of numerical control technique (NC). Its amplitude was measured under
the microscope. Meanwhile, the accuracy of the theoretical design was verified by comparing the
vibration conditions of horns with different shapes.

Table 1. Advantages and disadvantages of several commonly used horns

Shape Advantage Disadvantage
Stress concentration, prone to
Stepped-shaped Large amplification coefficient of amplitude
fracturing
Comparatively small amplification
Exponential Uniform stress distribution
coefficient of amplitude
Simple design and processing, comparatively Comparatively small amplification
Conical
low cost coefficient of amplitude
Comparatively large amplification coefficient
Medium amplification coefficient of
Catenary of amplitude, comparatively uniform stress
amplitude
distribution
Maximum shape factor, the maximum Comparatively complicated design and
Gaussian-shaped
amplitude can be acquired theoretically processing, comparatively high cost
Good matching of amplification coefficient of Comparatively complicated design and
Bezier Curve
amplitude and stress distribution processing, high cost

2. Design of ultrasonic horns

Fig. 1 shows the piezoelectric transducer system composed of Langevin vibrator and horn,
where the Langevin vibrator is made of four pieces of piezoelectric ceramic rings, front mental
block, back mental block, flange and bolt etc. The flange is located at the node of the system’s
vibration, for the purpose of fixing the system. The working frequency of Langevin vibrator is
53.7 kHz, and it works under first-order longitudinal vibration mode. The horn is made to work
under first-order longitudinal vibration mode by reasonably designing its shape. The curve of
displacement distribution of the entire system is shown in Fig. 1.

Fig. 1. Schematic of Langevin vibrator and horn

To acquire a new ultrasonic horn with large amplitude amplification ratio, the profile of the
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 1583. OPTIMIZATION DESIGN FOR ULTRASONIC HORN WITH LARGE AMPLITUDE BASED ON GENETIC ALGORITHM.
TAO HE, XIN-QUAN YE, YANG ZHAO

horn was designed to be a cubic Bezier Curve. The horn with the maximum amplitude ratio under
the frequency 53.7 kHz was determined by means of genetic algorithm. The cubic Bezier Curve
is determined by the following four points: starting point , control point of starting point ,
control point of end point and end point , as shown in Fig. 2. The starting point and end
point are determined by the radiuses ( and ) of the top and end of the horn and its length ,
while the curve shape is determined by the control point of starting point and control point of
end point . Bezier Curve is shown as follow:

= 1− +3 1− +3 1− + , (1)
= 1− +3 1− +3 1− + , (2)

where is the parameter, − and − are the lateral and longitudinal coordinates of point
− respectively.

Fig. 2. Bezier profile curve and its four control points , , and

The horn is axisymmetric. The optimized horn can be acquired by optimizing the positions of
control point and in Fig. 2. The optimization design is carried out by means of
Non-dominated Sorting Genetic Algorithm which can be used for solving multi-objective
constraint problems. Non-dominated sorting genetic algorithm is used to the optimization of the
horn profile. The following are performed in each generation of the genetic algorithm evolution
process.
1) Select the parents: parents, which are fit for reproduction, are selected for reproduction to
generate offspring. The genetic algorithm uses a binary tournament selection and the
crowded-comparison operator. In the binary tournament selection process, two individuals are
selected at random and their fitness is compared. The individual with better fitness is selected as
a parent. The crowded-comparison operator guides the selection process at the various stages of
the algorithm toward a uniformly spread-out Pareto-optimal front.
2) Perform crossover and mutation operator on the selected parents: the algorithm uses
simulated binary crossover and polynomial mutation.
3) Perform selection from the parents and the offspring: once the population is sorted based on
the non-dominated sorting algorithm, only the best solutions are selected.
4) Replace the unfit individuals with the fit individuals to maintain a constant population size.
During the optimization, the working frequency , radiuses ( and ) at the top and end of the
horn as well as the are defined first. The objective function of the optimization design is:

Min: − , (3)
Max: = , (4)

where is the first-order resonant frequency acquired from each generation of calculation, is

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 1583. OPTIMIZATION DESIGN FOR ULTRASONIC HORN WITH LARGE AMPLITUDE BASED ON GENETIC ALGORITHM.
TAO HE, XIN-QUAN YE, YANG ZHAO

the amplitude amplification ratio.

The genetic algorithm optimization procedure used in this investigation is programmed with
the commercial software MATLAB 7.0. The shape of the horn was obtained by controlling the
positions of design variables and . Finally, it was imported into finite element analysis
software to calculate and acquire the resonant frequency and amplitude amplification ratio
of each generation of horns. The optimized solution was acquired and saved by judging and
comparison.

Fig. 3. Flowchart of the optimization procedure

3. The optimized horn

3.1. Finite element analysis model

The vibration mode of the transducer was analyzed by ANSYS software to obtain the
frequency and vibration conditions of the horn. Fig. 4(a) shows the Langevin vibrator and Bezier
horn as well as their three-dimensional sizes. The diameters of the top and the end are and ,
its length is . Fig. 4(b) shows the mesh generation diagram in ANSYS modal analysis. In the
mesh generation, the element type of piezoelectric ceramic ring is 20-node hexahedral solid226,
while other parts are 20-node hexahedral solid95.

a)

b)
Fig. 4. a) Schematic of assembly, b) mesh generation for three-dimension finite element model

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 1583. OPTIMIZATION DESIGN FOR ULTRASONIC HORN WITH LARGE AMPLITUDE BASED ON GENETIC ALGORITHM.
TAO HE, XIN-QUAN YE, YANG ZHAO

Before modal analysis, point coupling was carried out on the surface of piezoelectric ceramics,
with voltage applied. The front and back block as well as the bolt of Langevin vibrator are all
made of ideal linear elastic materials. The front and back block are made of stainless steel and
aviation aluminum respectively, and the bolt and horn are made of titanium alloy. The
piezoelectric ceramics are made of four piezoelectric ceramic rings polarizing along direction.
The polarization directions of any two adjacent ceramic rings are opposite. The parameters of the
materials are as shown in Table 2.

Table 2. Piezoelectric ceramics (PZT-4), 7075-T651 aluminum, 303 stainless steel, and TC4
Material Properties Tensor ( , , , , , )
15.1 0 0
−5.2 0 0
Piezoelectric constant −5.2 0 0
matrix (C·m-2) 0 12.7 0
0 0 0
0 0 12.7
13.9 7.78 7.43 0 0 0
7.78 13.9 7.43 0 0 0
PZT-4 Rigidity matrix 7.43 7.43 11.5 0 0 0
(1010×N·m-2) 0 0 0 3.06 0 0
0 0 0 0 2.56 0
0 0 0 0 0 2.56
728.5 0 0
Dielectric constant
-1
(F m ) 0 728.5 0
0 0 634.7
Density (kg m-3) 7500
Young’s modulus (GPa) 71.1
Aluminum
Poisson’s ratio 0.33
(7075-T651)
Density (kg m-3) 2810
Young’s modulus (GPa) 200
303 stainless steel
Poisson’s ratio 0.28
(Y1Cr18Ni19)
Density (kg m-3) 7840
Young’s modulus (GPa) 110
TC4
Poisson’s ratio 0.33
Titanium alloy
Density (kg m-3) 4430

3.2. Numerical analysis

In genetic algorithm process, the number of generations was set as 30, and the population
of each generation was taken as 20. In the calculation, = 40, 50, 60, 70 and 80 were also
calculated. However, the calculation results were not improved. Therefore, = 30 was set in the
design. The length of the horn as well as the diameters of its top and end and were 53 mm,
6.36 mm and 1 mm respectively. The working frequency was determined by Langevin vibrator. It
was a constant value of 53.7 kHz. In the design, each individual was subject to modal analysis and
harmonic response analysis, and the first-order resonant frequency and amplitude amplification
ratio were obtained. Fig. 4 shows the normalized frequency response curve between the
vibrator and the horn under longitudinal excitation. In the frequency range of 0-100 kHz, there are
three longitudinal resonant frequencies in the system, including 53.87 kHz, 63.80 kHz and
82.43 kHz. It’s obvious that the amplitude of longitudinal vibration with the frequency of
63.80 kHz is larger than the amplitude of the vibration with the frequencies of 53.87 kHz and
82.43 kHz. However, when the excitation frequency of the system approaches to 53.87 kHz, the
second-order longitudinal frequency will not be excited. In the range of 0-100 kHz, the transducer
system composed of vibrator and horn also presents other response modes. However, other modal
responses are small, so only the 3 longitudinal resonant modes among them are given.
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 1583. OPTIMIZATION DESIGN FOR ULTRASONIC HORN WITH LARGE AMPLITUDE BASED ON GENETIC ALGORITHM.
TAO HE, XIN-QUAN YE, YANG ZHAO

Fig. 5. Normalized frequency response curve

a) 49.41 kHz

b) 53.87 kHz

c) 58.19 kHz
Fig. 6. Three modes surrounding the working frequency

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 1583. OPTIMIZATION DESIGN FOR ULTRASONIC HORN WITH LARGE AMPLITUDE BASED ON GENETIC ALGORITHM.
TAO HE, XIN-QUAN YE, YANG ZHAO

Fig. 6 shows the frequency of 56 kHz as well as the 3 inherent modes surrounding it, including
bending vibration (Fig. 6(a)), longitudinal vibration (Fig. 6(b)) and torsional vibration (Fig. 6(c)).
They are far different from surrounding modal frequencies (exceeding 8 %). Therefore, these
interferential modes are assumed as not existing in actual work. This assumption was verified in
subsequent experiment. Fig. 7 shows the population distributions of several generations in the
optimization design (the 10th generation, the 20th generation and the 30th generation). The
horizontal ordinate is Δ = − , and the vertical coordinates is amplitude amplification ratio,
i.e., the ratio between the amplitudes at the top and the end of the horn. According to the figure,
when the algorithm enters the 30th generation, the amplitude amplification ratio will increase
significantly.

Fig. 7. Population distribution of several generations in the optimization design

Fig. 8. Curve of profiles of the four horns

Fig. 8 shows an optimized Bezier horn acquired as well as the positions of its four control
points. To compare the designed Bezier horn and horns with other shapes, the researchers designed
stepped-shaped and conical horns with the same inherent frequency and area factors as the Bezier
horn, and designed constant section horns with the same inherent frequency as the Bezier horn.
Fig. 8 also lists the profile curves of these three horns. The length of stepped-shaped horn is
42 mm, the area change position is located in the middle of the horn (21 mm). Fig. 9 shows the
curve of distribution of vibration displacements along the normalized length of the horns based on
finite element calculation. It shows that the amplitude amplification of the designed Bezier horn
is about 1.73 times as large as the amplitude amplification of the conical horn. Fig. 10 shows the
curve of equivalent stress distribution along the normalized length of the four horns based on finite
element calculation. For stepped-shaped horn, its stress mutation reaches the maximum value at
the area mutation position. The stress of Bezier horn is comparatively small and uniform compared
with that of others. This benefits from its shape which is close to “campaniform”, and its stress
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 1583. OPTIMIZATION DESIGN FOR ULTRASONIC HORN WITH LARGE AMPLITUDE BASED ON GENETIC ALGORITHM.
TAO HE, XIN-QUAN YE, YANG ZHAO

distribution matches well with its cross-sectional area. Table 3 lists the amplitude amplification
times and the maximum equivalent stress of the four horns. Although the stepped-shaped
horn has large amplitude, its maximum stress is also very large. With the increase of excitation
voltage, it will fracture first; while Bezier horn has high amplitude amplification times and small
stress simultaneously.

Fig. 9. Distribution of vibration displacements along the normalized length of the horns

Fig. 10. Equivalent stress distribution along the normalized length of the horns

Table 3. Comparison of the four types of the horns

Shape / Length Amplification coefficient (MPa)
Bezier 6.36 53 10.2 595.5
Stepped-shaped 6.36 42 15.4 68.3
Conical 6.36 53 5.9 98.7
Constant section 1 45 1 144.2

4. Experimental measurement

The model of the optimized horn was built by UG, which was assembled with vibrator, as
shown in Fig. 11. It was manufactured by numerical control technology. Firstly, the admittance
and phase curve (analysis frequency range of 48-58 kHz) of the transducer vibration system was
measured by LCR-8101 precise impedance meter under small signal excitation (1 ). As shown
in Fig. 12, its harmonic frequency is 53.167 kHz, which is 1.3 % less than the ANSYS numerical
calculation result (53.87 kHz). There is only one resonance peak in the analysis frequency range,
which is conducive to restraining other vibration modes in the system from disturbing the required
vibration mode.
As the amplitude exceeds 10 µm, the amplitude can be directly observed at the vibration end

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 1583. OPTIMIZATION DESIGN FOR ULTRASONIC HORN WITH LARGE AMPLITUDE BASED ON GENETIC ALGORITHM.
TAO HE, XIN-QUAN YE, YANG ZHAO

face with long-focus microscope. The schematic diagram of the measurement device is as shown
in Fig. 13. The sinusoidal signal output by the signal generator (RIGOL DG1022) was switched
in the vibrator via power amplification (LM3886). The signal frequency was adjusted, and the
voltage signal of the input vibrator was observed by digital oscilloscope (RIGOL DS 5022) to
make the ultrasonic transducer work under resonant state. The vibration image of the output of the
horn was transmitted to PC via microscope digital camera (DCM136). The vibration conditions
of the ends of the horn were displayed by software on a real-time basis (ScopePhoto3.0).

Fig. 11. Model of Bezier horn and Langevin vibrator system

Fig. 12. Admittance and phase curve

Fig. 14(a) and Fig. 14(b) show the vibration conditions of the ends of the Bezier horn under
static state and resonant state as observed by microscope. Through comparison, it’s obvious to
judge that the vibration of the horn is longitudinal vibration, while bending vibration and torsional
vibration are very small. According to Fig. 14(b), the tracing and measurement for the marked
point show the vibration displacement of the horn. To carry out comparison, conical horn was
processed and measured simultaneously, with the resonant frequency of 53.65 kHz. Under the
excitations of corresponding resonant frequencies, the relationship between the two horns and the
voltage is as shown in Fig. 14. The figure shows that the amplitudes of the horns all increase with
the increase of the voltage. Under the same excitation, the average amplitude of Bezier horn is
73.5 % larger than that of conical horn. This is very close to the results from simulation (Table 3).
This further verifies the reliability of the simulation results.

Fig. 13. Schematic diagram of the experiment for ultrasonic horn

Fig. 16 shows the frequency response curves of the horn in simulation and experiment. The
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 1583. OPTIMIZATION DESIGN FOR ULTRASONIC HORN WITH LARGE AMPLITUDE BASED ON GENETIC ALGORITHM.
TAO HE, XIN-QUAN YE, YANG ZHAO

frequency of the designed horn is 53.87 kHz, while the experiment frequency is 53.167 kHz. The
two are well consistent. The actual working frequency is slightly less than the frequency of finite
element simulation due to many reasons: (1) the difference between actual and theoretical
properties of the material, such as density and Young’s modulus, (2) errors due to processing,
(3) failing to consider damping during simulation, but there is certain damping. If damping exists,
the frequency of the system will be slightly less than that under non-damping condition. (4) With
the work time progressing, the system will become heat, and the material properties will change,
and the frequency will reduce.

a) The static vibration image b) The dynamic vibration image

Fig. 14. Comparison between the static and dynamic vibration

Fig. 15. Relationship between the vibration amplitude and voltage

Fig. 16. Frequency response curves of the horn

5. Conclusions

On the basis of analyzing and comparing the advantages and disadvantages of existing horns

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 1583. OPTIMIZATION DESIGN FOR ULTRASONIC HORN WITH LARGE AMPLITUDE BASED ON GENETIC ALGORITHM.
TAO HE, XIN-QUAN YE, YANG ZHAO

and from the perspective of improving the vibration amplitude of the ultrasonic horn, a horn with
the profile of cubic Bezier Curve is designed by means of ANSYS software simulation and
multi-objective genetic algorithm. The horn of this shape not only has large amplitude, but also
has small stress distribution. Therefore, it is more practical. The transducer system composed of
Langevin vibrator and Bezier horn is processed and measured. Meanwhile, a conical horn with
the same frequency is also processed. The actually measured frequency is very close to the
theoretical frequency. The vibration amplitude of the Bezier horn and conical horn are measured
by optical microscope and relevant software. The experiment shows that when the excitation
voltage is less than 160 , the average amplitude of Bezier horn is 73.5 % larger than that of
the conical horn. When the excitation voltage is 200 , the amplitude of the system can reach
108um. The research integrates the methods such as finite element and optimization design etc.,
which is conducive to providing new thought for designing ultrasonic horn.

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 1583. OPTIMIZATION DESIGN FOR ULTRASONIC HORN WITH LARGE AMPLITUDE BASED ON GENETIC ALGORITHM.
TAO HE, XIN-QUAN YE, YANG ZHAO

Tao He received the M.E. degree in Mechanical Engineering from WuHan University of
Technology, China, in 2008. He is currently a Lecturer in the mechanical engineering, the
WenZhou University, China. His current research interests are in the areas of intelligent
detection and control, the complex system optimization. He has worked intensively on
designing, analyzing and evaluating practical algorithms with the theoretical basis, as well
as building prototype systems.

Xinquan Ye received the B.E. degree in Mechanical Engineering from TianJin University
of Science and Technology, China, in 1982. His current research interests are in the areas
of high/low voltage electrical equipment system, the complex system optimization,
stochastic optimization.

Yang Zhao received M.S. degree in School of Electronic and Electrical Engineering from
ChangChun University of Technology in 2008. He works in Department of Electronic and
Information Technology, Jiangmen Polytechnic since 2008. His research interests are in
the areas of predictive control, intelligent control and optimization algorithm.

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