Design Enhancement an‎d Acoustic Field Simulation of High-Power Ultrasonic Processing Horns in Liquid Environments

10/22/2025 12:00:00 AM

In recent years, with the advancement of technology an‎d the growing deman‎d for higher-quality industrial processes, innovative methods for homogenization have been developed among which the ultrasonic technique has gained particular prominence. This method utilizes ultrasonic waves an‎d the phenomenon of cavitation to transfer mechanical energy into a fluid, generating intense shear forces an‎d bubble collapses that lead to particle disintegration an‎d uniform dispersion. Compared with conventional mechanical approaches, ultrasonic homogenization offers higher efficiency, more precise controllability, an‎d the ability to achieve homogeneity at the nanoscale. However, due to the multiphysics nature of this technology an‎d the complex interaction between the vibrational field an‎d the acoustic field, a comprehensive understan‎ding of pressure distribution an‎d effective cavitation zones within various media still requires further investigation. Hence, experimental an‎d numerical analyses of the acoustic field surrounding ultrasonic horns with different geometries play a vital role in optimizing design parameters an‎d improving process efficiency. In this study, the vibrational behavior of ultrasonic horns was first examined using a gap sensor to measure displacement amplitude at different power levels, revealing a linear relationship between input power an‎d vibration amplitude. Subsequently, the aluminum foil erosion test was employed to characterize the spatial distribution of the acoustic field around the horn. Finally, numerical simulations were carried out in COMSOL Multiphysics, including both modal analysis an‎d acoustic field analysis, to reproduce the pressure distribution near the horn. The numerical results were then compared with experimental data, showing excellent agreement an‎d validating the accuracy of the developed model.

فراصوت , همگن سازي , كاويتاسيون , ميدان آكوستيك , هورن

Ultrasonic , Homogenization , Cavitation , Acoustic field , Horn

Ashkan Safarbali

Rezvan Abedini