Air actuated ultrasonic tool

An ultrasonic tool comprising:

• an actuation controller for generating a predetermined air pressure within the tool, the predetermined air pressure corresponding to a desired actuation force;
• an air actuated acoustic horn assembly coupled to the actuation controller for applying the actuation force to a part based on the predetermined air pressure, the horn assembly transmitting mechanical vibrations to the part at a predetermined frequency;
• and
• an acoustic control system coupled to the horn assembly, the acoustic control system transferring high frequency electrical voltage to the horn assembly.

An air actuated acoustic horn assembly comprising:

• an acoustic horn having a longitudinal bore, the acoustic horn transmitting mechanical vibrations to a part at a predetermined frequency;
• a plunger mechanism nodally disposed within the longitudinal bore of the acoustic horn, the plunger mechanism having a stationary portion coupled to the horn and a movable portion;
• and
• an air channel configuration providing an air pathway between an actuation controller and the movable portion of the plunger mechanism such that air pressure generated by the actuation controller causes the movable portion to extend from the horn and apply a force to the part.