Design, Analysis and Manufacturing of a Bone Cutting Ultrasonic Horn-Tool and Verification with Experimental Tests

Document Type: Research Paper


1 Department of Mechanical Engineering, Isfahan University of Technology, Isfahan, Iran

2 Department of Mechanical Engineering, University of Kashan, Kashan, Iran

3 Department of Mechanical Engineering, Payame Noor University, Tehran, Iran


Horn is one of the main components of ultrasonic cutting systems. The most important characteristics of the horn design are its resonant frequency and amplification factor. Closed-form equations can be used only for the design of simple horns and do not apply to more complex shapes like surgical tools. In This paper, a designing technique based on the finite element method and experimental tests is presented. The conventional design methods are improved, and designing a high performance surgical ultrasonic horn for bone cutting tools is facilitated. The new and complex bone cutting tool has both the knife-edge and toothed-edge, which could cut the bone easily and accurately. The investigations of cutting forces applied to the tool edges show less force in the toothed edge than the knife edge.


Main Subjects

[1] Nad, M., Cicmancova, L., The effect of the shape parameters on modal properties of ultrasonic horn design for ultrasonic assisted machining, Proceedings of the 8 th International Conference DAAAM-Industrial Engineering, Tallinn-Estonia, 57-62, 2012.

[2] Premoli, M., Bonini, S. A., Mastinu, A., Maccarinelli, G., Aria, F., Paiardi, G., Memo, M., Specific profile of ultrasonic communication in a mouse model of neurodevelopmental disorders, Scientific Reports, 9, 2019, 1-12.

[3] Scopelliti, M. G., Chamanzar, M., Ultrasonically sculpted virtual relay lens for in situ microimaging, Light: Science & Applications, 8, 2019, 1-15.

[4] George, R., Evaluation of the evidence of effectiveness of ultrasonic activated irrigation for root canal treatment, Evidence-Based Dentistry, 20, 2019, 83-84.

[5] Kuang, Y., Sadiq, M., Cochran, S., Huang, Z., Design, and characterization of an ultrasonic surgical tool using d31 PMN-PT plate, Physics Procedia, 63, 2015, 182-188.

[6] Schmidbauer, S., Hallfeldt, K. K., Sitzmann, G., Kantelhardt, T., Trupka, A., Experience with ultrasound scissors and blades (UltraCision) in open and laparoscopic liver resection, Annals of Surgery, 235, 2002, 27.

[7] Gossot, D., Buess, G., Cuschieri, A., Leporte, E., Lirici, M., Marvik, R., Meijer, D., Melzer, A., Schurr, M., Ultrasonic dissection for endoscopic surgery, Surgical Endoscopy, 13, 1999, 412-417.

[8] Lucas, M., Cardoni, A., Macbeath, A., Temperature effects in ultrasonic cutting of natural materials, CIRP Annals-Manufacturing Technology, 54, 2005, 195-198.

[9] Nánási, T., The effect of non-conservative load on the stability limits of compressed beams, Acta Mechanica Slovaca, 11, 2007, 311-316.

[10] Seah, K., Wong, Y., Lee, L., Design of tool holders for ultrasonic machining using FEM, Journal of Materials Processing Technology, 37, 1993, 801-816.

[11] Shu, K.-M., Chen, J.-W., The Design of Acoustic Horns for Ultrasonic Aided Tube Double Side Flange Making, International Journal of Mechanical, Aerospace, Industrial, Mechatronic and Manufacturing Engineering, 9, 2015, 103-109.

[12] Roy, S., Design of a circular hollow ultrasonic horn for USM using finite element analysis, International Journal of Advanced Manufacturing Technology, 93, 2017, 319-328.

[13] Dipal, A., Patel, M., Avadhoot, B., Rajurkar, U., Analysis of Different Shaped Sonotrodes used for Plastic Welding, Institute of Technology, Nirma University, Ahmedabad, 2011.

[14] Behera, B., Sahoo, S., Patra, L., Rout, M., Kanaujia, K., Finite Element Analysis of Ultrasonic Stepped Horn, National Institute of Technology, Rourkela–769, 8, 2011, 68-77.

[15] Na, M., Ultrasonic horn design for ultrasonic machining technologies, Applied and Computational Mechanics, 4, 2010, 68-78.

[16] Qiu, Y., Huang, Z., Slade, A., Thomson, G., Optimization of ultrasonic tool performance in surgery, 4th European Conference of the International Federation for Medical and Biological Engineering, Springer, 899-902, 2009.

[17] Nanu, A. S., Marinescu, N. I., Ghiculescu, D., Study on ultrasonic stepped horn geometry design and FEM simulation, Nonconventional Technologies Review, 4, 2011, 25-30.

[18] Guiman, M. V., Roșca, I. C., A New Approach on Vibrating Horns Design, Shock and Vibration, 116, 2017, 265-272.

[19] Jie, G., Optimization design of compound ultrasonic horns and analysis of acoustic characteristics, Journal of Shaanxi Normal University (Natural Science Edition), 4, 2006, 203-208.

[20] Zhang, X., Qian, H., A Vibration system for rotary ultrasonic machining, Journal of Vibration and Shock, 29, 2010, 212-221.

[21] Wang, D.-A., Chuang, W.-Y., Hsu, K., Pham, H.-T., Design of a Bézier-profile horn for high displacement amplification, Ultrasonics, 51, 2011, 148-156.

[22] Shu, K. M., Hsieh, W. H., Yen, H. S., Design and Analysis of Acoustic Horns for Ultrasonic Machining, Applied Mechanics and Materials, 662-666, 2013.

[23] Shu, K.-M., Hsieh, W.-H., Yen, H.-S., On the design and analysis of acoustic horns for ultrasonic welding, Transactions of the Canadian Society for Mechanical Engineering, 37, 2013, 905-916.

[24] Wang, H., Sun, C., Finite Element Analysis and Test of an Ultrasonic Compound Horn, World Journal of Engineering and Technology, 5, 2017, 351.

[25] Webster, A. G., Acoustical impedance and the theory of horns and of the phonograph, Proceedings of the National Academy of Sciences, 5, 1919, 275-282.

[26] Roşca, I. C., Chiriacescu, S. T., Creţu, N. C., Ultrasonic horns optimization, Physics Procedia, 3, 2010, 1033-1040.

[27] Coffignal, G., Touratier, M., A computer aided design program for the tuning of ultrasonic machining tools using the Finite element method, Proc. 5th Int. Modal Analysis Conf., England, 1987.

[28] Parrini, L., New technology for the design of advanced ultrasonic transducers for high-power applications, Ultrasonics, 41, 2003, 261-269.

[29] Roh, Y., Lee, S., Woo, J., Kang, K., Design and Construction of an Acoustic Horn for High Power Ultrasonic Transducers, Ultrasonics Symposium, IEEE, 1922-1925, 2006.

[30] ABAQUS 6.14-1 User Documentation. 2014.

[31] Iso, E., Mechanical properties of fasteners made of carbon steel and alloy steel–Part 1: Bolts, screws and studs with specified property classes–Coarse thread and fine pitch thread (ISO 898-1: 2013), 2013.

[32] 2017.

[33] Johnson, L., Microstructural Characterisation of Structural Bolt Assemblies in Fire, University of Sheffield, UK, 2014.

[34] Kornmann, X., Huber, C., Microstructure and mechanical properties of PZT fibres, Journal of the European Ceramic Society, 24, 2004, 1987-1991.

[35] Al-Budairi, H. D., Design and analysis of ultrasonic horns operating in longitudinal and torsional vibration, Ph. D., University of Glasgow, 2012.

[36] Casset, F., Devos, A., Sadtler, S., Le Louarn, A., Emery, P., Le Rhun, G., Ancey, P., Fanget, S., Defaÿ, E., Young modulus and Poisson ratio of PZT thin film by Picosecond Ultrasonics, IEEE International Ultrasonics Symposium, 2180-2183, 2012.

[37] Abdullah, A., Malaki, M., On the damping of ultrasonic transducersʼ components, Aerospace Science and Technology, 28, 2013, 31-39.

[38] Kei-Lin, K., Ultrasonic vibrating system design and tool analysis, Transactions of Nonferrous Metals Society of China, 19, 2009, s225-s231.

[39] Alam, K., Qamar, S. Z., Ultrasonically assisted bone drilling—effect of process parameters on delamination, Materials and Manufacturing Processes, 33, 2018, 1894-1898.