The ultrasonic plastic cutting process’s primary function is to split the connected parts. The high-frequency vibration per second can reduce the pressure acting on the items to be cut to facilitate a neat and clean cutting surface. Ultrasonic plastic cutting uses ultrasonic waves to melt the plastic being cut by localised heating, thus cutting the material.
Each object has a specific resonant frequency at which the item will vibrate strongly and cause a rupture. Applying a distinct external force against that particular frequency can produce a large vibration even with small detail, a resonance phenomenon. The cutting edge is made to vibrate more using resonance technology.
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How does it work
The ultrasonic plastic cutting knife vibrates 30,000 times per second (30 kHz) with a maximum output of 300 W. The ultrasonic cutter can easily cut resin, rubber, nonwoven fabric, and composite materials because of this movement. The cutting knife is made with 1mm thick wear-resistant carbide blades, and the user can replace the blades themselves, which can increase the life of the cutting knife and reduce the cost of use. In addition to excellent maintainability, our products are also environmentally friendly as they essentially do not emit any debris, wastewater, noise or fumes.
Ultrasonic plastic cutting consists of an “ultrasonic transducer” that generates vibrations and an “ultrasonic generator” that drives the transducer. The piezoelectric element (piezoelectric ceramic) is inside the transducer. The ultrasonic generator applies an AC voltage to the piezoelectric element at the same frequency as the transducer, which triggers the resonance of the entire vibrator, including the tool blade. The ultrasonic transducer has a feedback control system that transmits information about the frequency or amplitude deviation caused by the ultrasonic generator’s cutting load. The feedback control system maintains the resonance state and amplitude stability of the cutting head so that the tool always cuts the material quickly and cleanly.
The ultrasonic plastic cutting uses a replacement blade head with a thickness of 1mm and is made of alloy steel. The sharp head makes the cutting contact surface smaller and reduces the head’s heat. The sharp cutter uses ultrasonic to make the cutting effect more ideal. Ultrasonic plastic cutting can be used for hand-held cutting and automatic mechanical clamping. HCSONIC provides 20, 30, 35 and 40kHz ultrasonic cutter for different application environments.
Applications of ultrasonic cutting
Ultrasonic cutting has gained widespread use in the textile and food industries in recent years; it can precisely cut textiles, rubber, thermoplastic films, knitted and non-knitted materials, and various food products. Ultrasonic cutting includes handheld equipment and multiple systems integrated into automated machines. The advantages of ultrasonic cutting are precise cutting, pressure-free cutting (to avoid deformation of soft cut materials, such as cakes), welding while cutting specific material edges, fast cutting and significantly reduced cleaning costs.
Two factors affecting the ultrasonic plastic cutting
The term “amplitude” describes the microscopic displacement of the tool head’s cutting surface vibration. Amplitude is adjusted mechanically by the ultrasonic amplitude lever and digitally by the ultrasonic generator. The amount of amplitude affects the cutting process and must be adjusted to suit each application’s needs.
The speed at which the ultrasonic plastic cutting knife enters and advances through the material being cut is also a process variable adjusted for each cutting process. Sometimes it is necessary to slowly penetrate the product’s casing to avoid distortion and then increase the cutter’s speed through the development to achieve the best cut.
Advantages of ultrasonic plastic cutting
- Pressure-free cutting prevents the deformation of cut items.
- No heat is generated in the product, and the mould stays cold.
- With higher quality cutting, no mixing or breaking layers during cutting
- Significantly reduced material “ploughing” effect compared to mechanical cutting machines.
- Edge sealing for non-woven and textile cutting at the same time, avoiding burrs.
- Robust one-piece tool head blade construction virtually eliminates breakage and energy loss.
- Many standard carbide cutting blades are available for applications of all shapes and sizes.
- Ultrasonic cutting is cleaner than conventional cutters, with minimal debris and no adherence to cut items.
- Ultrasonic cutting saves space and minimises outgassing, resulting in more accurate cuts.
- The ultrasonic cutter features replaceable carbide cutting inserts for extended tool life.