How Ultrasonic Rubber Cutting Works

For rubber products, cold cutting is more suitable than thermal cutting. Cold cutting has the advantages of generating less heat, less thermal deformation, less dust generated during the cutting process, and the section will not be aged and cracked due to high temperature. Ultrasonic rubber cutting technology belongs to cold cutting, which uses ultrasonic energy, the rubber to be cut locally heated melting, to achieve the purpose of cutting the material. It can solve low productivity and personal safety in traditional rubber cutting.

How Does Ultrasonic Rubber Cutting Work

The ultrasonic rubber cutting principle is to convert 50/60Hz current into 20-40kHz electrical energy through an ultrasonic generator. The converted high-frequency electrical energy is converted again into mechanical vibrations of the same frequency through a transducer. The mechanical vibrations are then transmitted to the cutting knife through amplitude modulators that can change the amplitude. The ultrasonic rubber cutter vibrates at an amplitude of 10-70 μm along its length, repeating 40,000 times per second (40 kHz) (the vibration of the blade is microscopic and difficult to see with the naked eye). The cutting knife then transfers the received vibration energy to the workpiece's cutting surface to be cut. In this area, the vibration energy is used to cut the rubber by activating the rubber molecular energy and opening the molecular chains.

 Why You Should Consider It

The traditional rubber cutting technology needs to lubricate the rubber when cutting. There is a slow cutting speed, a large number of dust and debris generated by the large cut, uneven cutting surface, sticky knife and other phenomena. Many companies are still using traditional manual methods for cutting, failing to meet productivity and bringing hidden danger to life safety.

For rubber products, cold cutting is more suitable than thermal cutting. Cold cutting has the advantages of generating less heat, less thermal deformation, less dust generated during the cutting process; the section will not be too high temperature and ageing cracking. Ultrasonic rubber cutting technology belongs to cold cutting, which uses ultrasonic energy, the rubber being cut local heating melting, to cut the material. Ultrasonic rubber cutter can easily cut resin, rubber, plastic, fabric, and various overlapping composites.

The Four-Part Ultrasonic Rubber Cutting System

An ultrasonic generator (power supply)

The ultrasonic generator converts the 110VAC or 220VAC electrical supply current into a high frequency, high voltage electrical signal.

An ultrasonic converter (transducer)

The ultrasonic converter utilizes the high-frequency electrical signal from the generator and converts it into linear, mechanical movement. This conversion occurs using piezoelectric ceramic disks that expand when a voltage is applied.  The transducer used for ultrasonic rubber cutting is specially designed to introduce and flow air in and out for cooling.

An ultrasonic booster

The ultrasonic booster is a tuned component that mechanically adjusts the amount of linear vibratory movement from the converter to the required level for the specific application to produce optimal cutting performance. The booster also provides a safe, non-vibrating location to clamp onto the cutting tools.

An ultrasonic cutting tool (horn/sonotrode)

The ultrasonic cutting horn is a custom made tool that is engineered to vibrate at a specific frequency. These tools are painstakingly designed using computer modelling technology for optimum performance and longevity. Ultrasonic tools must be tuned to match the frequency of the system. This tuning procedure requires considering the horn’s mass, length and geometry. HCSONIC offers a wide range of configurations, each designed for a specific application, strictly ensuring good long-term performance.

Rubber cutting system (optional)

Correct positioning and rubber and ultrasonic cutter can be achieved using automated machines. Automation is essential to achieve the correct cutting position, direction and speed. Typically, these handling systems utilize servo-driven mechanisms to precisely control the rubber and cutting tools' speed and position.

 

Benefits of Ultrasonic Rubber Cutting

Very high precision cutting — the cuts are smooth, clear, and clean.

Repetitive cutting — a closed-loop electrical circuit monitors the blade output to provide consistent cuts time after time.

Cool temperature — little heat is imparted to the rubber.

Dry — no lubrication is needed since the vibrating cutting tool passes smoothly through the rubber while ultrasonically vibrating at 20,000 to 40,000 cycles per second, depending on the application.

Low energy consumption — the vibrating cutting horn is only activated when cutting, yielding approximately 100 watts or less during a typical thin material application.

Easy to integrate into automation - The ultrasonic rubber cutting process is simple and can be upgraded into existing machinery or installed in new equipment.

Ultrasonic Rubber Cutting System tips

High-frequency vibration applied to cutting tools does provide significant benefits. Primarily, ultrasonic technology enhances the cut quality and consistency and can easily cut resin, rubber, plastic, fabric, and various overlapping composites. HCSONIC can evaluate your rubber cutting operation's key factors to determine if an ultrasonic knife's low friction cutting surface might be a fit.

 

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