The flextensional class V ‘cymbal’ transducer has been widely adopted for low power ultrasonics applications,exhibiting high output displacement for low input energy, compared to a single ceramic, whenused as an actuator. Despite its performance benefits, the original designs of cymbal transducers haveinherent drawbacks for high power ultrasonics applications that require much higher output displacements.Asymmetries introduced during the fabrication process reduce the efficiency of the transducer,and degradation of the bonding layer between the end-caps and the electroactive material can alter thevibration response and ultimately lead to failure. A new design of the cymbal transducer is thereforeproposed that delivers high output displacements. A comparison is presented between a cymbal basedon the original design configuration and a new cymbal, to demonstrate the effects of input voltage levelson the dynamic characteristics and vibration response of the two different transducers. For the firstcymbal the end-caps are directly bonded to the piezoceramic disc using a commercial non-conductiveepoxy. The second cymbal incorporates a metal ring bonded to the outer edge of the piezoceramic disc toimprove the mechanical coupling with the end-caps, thereby enhancing the operational capability of thedevice at higher voltages, allowing for excitation of higher output displacements by removing the problemsassociated with failure in the epoxy layer. This design is demonstrated to be particularly suitablefor power ultrasonics applications such as miniature surgical devices, for example as drilling and cuttingdevices for orthopaedics procedures.
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