A planar Bézier profiled horn for reducing penetration force in ultrasonic cutting

•A planar Bézier horn with high displacement amplification and low stress concentration is developed.•The penetration force required to enter the workpiece using the Bézier horn is 75% of that of the traditional catenary horn.•The decrease in the penetration force is due to the high displacement amplification of the Bézier horn.

An ultrasonic planar horn with a Bézier profile is developed. The first longitudinal displacement mode of the horn is exploited for high displacement amplification in order to reduce the penetration force required to enter and cut materials. The displacement amplification and stress distribution characteristics of the Bézier horn and the commonly used catenary horn are examined. The penetration force by the Bézier horn is nearly 75% of that by the catenary horn with a penetration speed of 0.25 mm/s during cutting a tissue stimulant. At a penetration speed of 0.5 mm/s, the penetration force by the Bézier horn is nearly 85% of that by the catenary horn for cutting a polymethylmethacrylate (PMMA) material. The decrease in the penetration force by the Bézier horn is attributed to the fact that the displacement amplification of the Bézier horn is 30% higher than that of the traditional catenary horn with the same length and end surface widths.