Ultrasonic block horns are prone to reliability problems associated with modal activity close to the tuned operating frequency. This paper presents an approach to block horn design, which relies on two laser based vibration measurement techniques, electronic speckle pattern interferometry (ESPI) and laser doppler velocimetry (LDV) modal analysis, to validate finite element (FE) models. Block horn vibration characteristics are interpreted from experimental and theoretical data such that successful horn redesign can be achieved from modifications to the FE models.
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