How do you determine which ultrasonic welding booster ratio to use?

The ultrasonic booster ratio can affect the amplitude and energy of the ultrasonic vibrations and can influence the quality and strength of the weld.

The choice of booster ratio will depend on several factors, including the size and shape of the parts being welded, the material being welded, the desired weld strength, and the frequency of the ultrasonic vibrations.

To determine the appropriate booster ratio, it is necessary to consider the following:

1. The size and shape of the parts being welded: The booster ratio should be chosen so that the ultrasonic vibrations are distributed evenly across the parts being welded, ensuring that the weld is uniform and strong.
2. The material being welded: Different materials have different acoustic properties, which can affect the energy transfer during ultrasonic welding. The booster ratio should be chosen to optimize energy transfer for the specific material being welded.
3. The desired weld strength: The booster ratio can affect the strength of the weld, with higher booster ratios generally producing stronger welds. However, excessively high booster ratios can lead to excessive amplitude and energy transfer, resulting in over-welded parts.
4. The frequency of the ultrasonic vibrations: The booster ratio should be chosen to optimize energy transfer at the specific frequency of the ultrasonic vibrations being used.

In general, a booster ratio between 1:1 and 1:2 is suitable for most ultrasonic welding applications. However, the specific booster ratio will depend on the factors mentioned above and may require some experimentation to determine the optimal ratio for a given application.

Determining which booster to use for an ultrasonic application requires some planning. First you must understand the theoretical amplitude requirement for the material you are welding. Then you must determine the amplitude from the transducer. Transducer amplitude is fixed based on the frequency of the system.

To determine which ultrasonic booster ratio to use there are two formulas:

1) Transducer Amplitude X Booster Gain X Horn Gain = Amplitude.

2) Stack Amplitude > Resin Amplitude Requirement