Why ultrasonic plastic cutter is more popular and useful

Why ultrasonic plastic cutter is more popular and useful?

In the field of plastic processing, cutting technology is an extremely important part. Traditional cutting methods often expose many disadvantages when facing plastic materials, and the emergence of ultrasonic plastic cutting knives has brought new solutions to this field.

I. In-depth analysis of working principles

The operation of ultrasonic plastic cutting knives is based on unique acoustic and thermodynamic principles. Its core components include ultrasonic generators, transducers and cutting heads.

(I) Ultrasonic generator

The function of the ultrasonic generator is to convert ordinary mains electricity into high-frequency AC signals. This process is similar to "transforming" conventional current into a current form with a specific frequency. Generally speaking, the frequency it generates can be as high as 20kHz or even higher. For example, the common frequencies of 20kHz, 30kHz, 40kHz, etc. Different frequencies are suitable for plastic cutting needs of different thicknesses and materials. Higher frequencies can achieve finer cutting, while lower frequencies may be more advantageous when cutting thicker plastic materials.

(II) Transducer

The transducer shoulders the key mission of energy conversion. It receives high-frequency AC signals from the ultrasonic generator and efficiently converts electrical energy into mechanical energy through internal piezoelectric ceramics and other components, that is, generates ultrasonic vibrations. This ultrasonic vibration propagates in the medium at an extremely high frequency, providing an energy basis for the subsequent cutting process. Taking the piezoelectric ceramic transducer as an example, when an AC signal is applied to the piezoelectric ceramic, the piezoelectric ceramic will produce corresponding expansion and contraction deformation according to the frequency and intensity of the electrical signal. This rapid expansion and contraction deformation is the source of vibration. ​
(III) Cutting head​
The cutting head is the part that directly acts on the plastic material. The ultrasonic vibration generated by the transducer is transmitted to the cutting head through the amplitude rod, causing the cutting head to vibrate with a small amplitude at an extremely high frequency (such as tens of thousands of times per second). When the cutting head contacts the plastic material, its high-frequency vibration causes the molecules of the plastic material to produce intense friction. Due to the heat generated by molecular friction, the local temperature of the plastic material rises rapidly and reaches the melting point or softening point of the plastic. At this time, the plastic material is partially softened or even melted under the action of the cutting head, and the cutting head can easily separate the plastic material and complete the cutting process. For example, when cutting polycarbonate plastic, the high-frequency vibration of the blade quickly causes the plastic molecules in the contact area to generate heat by friction, and the originally hard plastic softens at high temperature, so that it can be cut smoothly. ​

II. Significant advantages are fully presented ​
Compared with traditional plastic cutting methods, ultrasonic plastic cutting knives have shown many significant advantages, which have made them gradually stand out in the plastic processing industry. ​

(I) Excellent cutting accuracy ​
Micro-size control: Traditional cutting tools, such as mechanical knives, are difficult to achieve high precision when cutting micro-sized plastic parts or performing fine cutting due to the physical size limitations of the blade. The vibration amplitude of the ultrasonic plastic cutting knife is extremely small, and the cutting position can be accurately controlled. In the electronics industry, for the cutting of tiny electronic component shells made of plastic, ultrasonic cutting knives can achieve sub-millimeter or even finer cutting accuracy, ensuring the dimensional accuracy of the component shell and meeting the strict requirements of electronic components for precision dimensions. ​
Excellent edge quality: Traditional cutting methods are prone to burrs, gaps or deformations on the cutting edges of plastic materials. During the cutting process, the ultrasonic cutter is cut by local heating and melting, so the cutting edge is relatively smooth and the heat-affected area is small. In the cutting of acrylic plastic plates, the edge after ultrasonic cutting can achieve a high surface quality without subsequent grinding, which greatly reduces the subsequent processing steps and improves production efficiency. ​

(II) Efficient and fast cutting ​
High-frequency vibration improves efficiency: The blade of the ultrasonic cutter vibrates at an extremely high frequency, up to tens of thousands of times per second. This high-frequency vibration enables the cutting process to be completed in a short time. Compared with traditional mechanical cutting, such as sawing or shearing, ultrasonic cutting is much faster. In the cutting production line of large-scale plastic pipes, the use of ultrasonic cutters can greatly increase the cutting speed, and the number of cuts per unit time is significantly increased, thereby improving the overall production efficiency. ​
Reducing material resistance: The high-frequency vibration of the blade head reduces the friction resistance between the blade and the plastic material. In the traditional cutting method, the friction between the blade and the material is large, which not only affects the cutting speed, but also easily causes the blade to wear. When cutting, the ultrasonic cutter has a small friction resistance, the cutting process is smoother, and it can quickly penetrate the plastic material, further improving the cutting efficiency.​

(III) Strong material adaptability​
Compatible with a variety of plastic materials: Whether it is common general plastics such as polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), or engineering plastics such as polycarbonate (PC), nylon (PA), etc., ultrasonic plastic cutting knives can adapt well. Although the melting points and molecular structures of different plastic materials are different, ultrasonic cutting knives can automatically adjust the cutting effect according to the characteristics of the material by locally heating and melting. For some elastic plastics or sticky plastics that are difficult to cut with traditional knives, ultrasonic cutting knives can also easily deal with them. ​
Advantages of composite material cutting: When facing plastic composite materials containing fiber-reinforced materials, traditional cutting methods are prone to fiber breakage, delamination and other problems. When ultrasonic cutting knives cut such composite materials, they can reduce damage to the fibers and maintain the structural integrity of the composite materials because they generate heat through molecular vibration. In the cutting of carbon fiber reinforced plastics (CFRP), ultrasonic cutting knives can achieve high-quality cutting, avoid fiber pullout and delamination, and ensure the performance of composite products.​

(IV) Extended tool life​
Reduced physical wear: During the plastic cutting process, the blade of a traditional cutting tool is easily worn and blunted due to direct friction and pressure between the material and the cutting tool. The ultrasonic plastic cutting tool's blade mainly softens the material for cutting through high-frequency vibration, rather than relying on a sharp blade for hard cutting. The relative movement between the blade and the plastic material greatly reduces physical wear, thereby extending the tool's service life. Under normal use, the life of an ordinary ultrasonic cutting blade can be extended several times or even dozens of times longer than that of a traditional mechanical cutting tool. ​
Self-cleaning function: During the cutting process, the high-frequency vibration of the blade also has a certain self-cleaning effect. Cutting products such as plastic debris are not easy to adhere to the blade, reducing the performance degradation and clogging of the tool caused by debris accumulation. This not only ensures the continuous and stable progress of the cutting process, but also further extends the effective use time of the tool, reducing the tool replacement cost and maintenance workload. ​

(V) Environmental protection and energy-saving characteristics​
Low energy consumption: During the working process of the ultrasonic plastic cutting knife, the main energy consumption is concentrated in the ultrasonic generator converting the mains electricity into high-frequency alternating current and the energy conversion link of the transducer. Compared with some traditional high-energy consumption cutting equipment, such as laser cutting machines, ultrasonic cutting knives consume significantly less energy. When meeting the same cutting requirements, the power consumption of ultrasonic cutting equipment may be only a fraction of that of laser cutting equipment. This can effectively reduce production costs for large-scale plastic processing companies, and it is also in line with the current social advocacy of energy conservation and emission reduction. ​
No pollution: Traditional cutting methods, such as flame cutting, may produce harmful gases and smoke, which pollute the environment; a large amount of debris generated by mechanical cutting also needs special treatment. During the cutting process, ultrasonic cutting knives do not produce harmful gases and liquid waste. The plastic debris generated by cutting is relatively small and easy to collect and treat, which has minimal pollution to the environment. It is a more environmentally friendly plastic cutting method.