1. What are ultrasonic waves?
Sound is a vibration that is transmitted through a medium, such as air, water, and metals.
Ultrasonic waves are an "inaudible sound," the frequency of which generally exceeds 20 kHz. A 20-kHz frequency means that a certain medium vibrates 20,000 times per second.
2. What is the cutting done by the ultrasonic cutter?
The ultrasonic cutter vibrates its blade with an amplitude of 10 - 70 µm in the longitudinal direction. The vibration is microscopic, so it cannot be seen. The movement repeats 20,000 - 40,000 times per second (20 - 40 kHz). Because of this movement, the ultrasonic cutter can easily cut resin, rubber, nonwoven cloths, film, composite materials in which various products are superposed, and food.
3. How does the ultrasonic cutter work?
The ultrasonic cutter is composed of a "transducer" that generates vibration and an "oscillator" that drives the transducer.
A piezoelectric element is used for the transducer. When voltage is applied, the piezoelectric element displaces the transducer by a few micrometers. Periodically applying voltage generates vibration.
Each object has its special frequency, by which the object is stable and easy to vibrate. By adding an external force that corresponds to that special frequency, a small force can obtain a large vibration. This phenomenon is called resonance. In the ultrasonic cutter, the piezoelectric element generates a force that resonates the whole body, from the transducer to the blade tip, generating a large vibration at the tip. The oscillator periodically generates voltage to resonate and drive the transducer. Using a component of the ultrasonic cutter called the horn to wring the cross-sectional area, from the piezoelectric element to the blade tip, can obtain a larger vibration.
4. What features does the SONOFILE® have?
A unique method of casing the blade (patent number: 3462118) saves time during alignment and blade-changing. Since the blade can be attached easily and accurately regardless of an operator's technical skill level, manufacturing processes become stable. When the ultrasonic cutter is used, the amount of cutting chips and dust is small, allowing manufacturing sites to remain clean.
The SONOFILE® also performs half-cutting of multilayer materials.
The SONOFILE® employs a feedback-control system, in which information transmitted from the transducer returns to the oscillator. This corrects disturbances of frequency and amplitude due to the load during cutting to always maintain the set value. The SONOFILE® also possesses an output adjustment function that can arbitrarily change the vibration magnitude to be most suitable for the finishing condition of a product.
[ Manufacturing examples ]
The SONOFILE® is designed to be built into apparatuses, such as robots and automated machines, as a cutting tool for cutting and deburring.
ON/OFF operation and amplitude change can be performed from the outside. The SONOFILE® can output error signals, such as overload notifications.
(Specifications vary according to the model.)
It can be used to:
+ Cut vehicle interior materials
+ Cut carbon fiber prepreg for aircrafts
+ Debur and gate-cut resin-molded products
+ Half-cut multilayer materials
It can also be used easily as a hand tool.
Other examples of how the SONOFILE® can be used:
+ To clean fossils
+ To cut breads
+ To cut geological sections (clay layers)
+ To remove rust, paint, and extraneous matter
+ To edge process film materials
(rounding of angular parts)