Log In

Come Join Us!

Are you an
Engineering professional?
Join Eng-Tips Forums!
  • Talk With Other Members
  • Be Notified Of Responses
    To Your Posts
  • Keyword Search
  • One-Click Access To Your
    Favorite Forums
  • Automated Signatures
    On Your Posts
  • Best Of All, It's Free!

*Eng-Tips's functionality depends on members receiving e-mail. By joining you are opting in to receive e-mail.

Posting Guidelines

Promoting, selling, recruiting, coursework and thesis posting is forbidden.

Students Click Here

Ultrasonic staking stop limit and horn contact

Ultrasonic staking stop limit and horn contact

Ultrasonic staking stop limit and horn contact


I am new to ultrasonics and plastic joining.

I am working on designing a fixture for ultrasonic staking of plastic part to a steel cover.

The Branson 2000ao welder we have does not have a weld by distance option with a linear encoder.

We plan to use a rectangular knurled face horn to strike the plastic bosses to form some head.
I am wondering about preventing the horn from hitting the steel cover and what could be done to prevent this.
I see this welder and many others come standard with a mechanical stop. The manual seems to suggest that this might not be a reliable or accurate enough way to prevent the horn from hitting the staked part.

I would expect only about 1 mm of head or so for my application.

I also see that common staking methods have the horn make contact with the metal surface. What are the implications of this? will it scream loudly and ruin the titanium horn?

Thank you all.

I know this is a small field so if anyone has any thoughts on this please let me know.

RE: Ultrasonic staking stop limit and horn contact

Could you apply a barrier material to the horn where it might contact the metal? Kapton tape, for example.

RE: Ultrasonic staking stop limit and horn contact

I like the idea. For production that could be tedious, as we plan to have 23 different angular locations to stake on a circular part.

I wonder how good the mechanical stop is on the machine. At the moment I just have the actuator without mounting and pneumatic control system, so I cannot test this yet.

If the welder is reasonably consistent then a contact point or mechanical stop would really just be an emergency measure to not damage the horn or other components.


Red Flag This Post

Please let us know here why this post is inappropriate. Reasons such as off-topic, duplicates, flames, illegal, vulgar, or students posting their homework.

Red Flag Submitted

Thank you for helping keep Eng-Tips Forums free from inappropriate posts.
The Eng-Tips staff will check this out and take appropriate action.

Reply To This Thread

Posting in the Eng-Tips forums is a member-only feature.

Click Here to join Eng-Tips and talk with other members! Already a Member? Login


Taking Control of Engineering Documents
This ebook covers tips for creating and managing workflows, security best practices and protection of intellectual property, Cloud vs. on-premise software solutions, CAD file management, compliance, and more. Download Now
The Great Project Profitability Debate
A/E firms have a great opportunity to lead the world into the future, but the industry’s greatest asset—real-time data—is sitting wasted in clunky, archaic ERP platforms. Learn how real-time, fully interactive dashboards in a modern ERP allow you to unlock data that will shape the future of the world. Download Now

Close Box

Join Eng-Tips® Today!

Join your peers on the Internet's largest technical engineering professional community.
It's easy to join and it's free.

Here's Why Members Love Eng-Tips Forums:

Register now while it's still free!

Already a member? Close this window and log in.

Join Us             Close