Optimizing multi-source ultrasound configuration for process intensification: numerical simulation and experimental validation

Abstract

This paper investigates the application of ultrasonic simulation in metallurgy, focusing on the effects of ultrasonic power density, number of transducers, and multi-source array mode on the acoustic field distribution characteristics. The simulation results reveal that as power density increases from 375 W/L to 750 W/L at 28 kHz, the maximum sound pressure rises from 4.13 × 10⁶ Pa to 4.37 × 10⁶ Pa, and the cavitation volume fraction increases from 19% to 50%. The maximum sound pressure (4.13 × 10⁶ Pa) and cavitation volume fraction (49%) of two transducers are higher than three transducers. The isosceles triangle array method exhibits the optimal sound field characteristics, with a maximum sound pressure of 2.87 × 10⁶ Pa and a cavitation volume fraction of 52%. The maximum sound pressure of 4.13 × 10⁶ Pa is achieved when two transducers are 45 mm from the reaction chamber bottom and the peak offset distance is zero. The simulation results are confirmed by measuring the sound pressure in water using a hydrophone under 140–200 W. This research visualizes the ultrasonic process intensification parameters, addressing the issue of random arrangement of transducer in industrial applications and enhancing work efficiency.