The difference between ultrasonic cutting technology and traditional processing technology

1, Compared with the traditional high speed milling in the processing of honeycomb materials

The basic principle of the traditional high speed milling and drilling technology is to use the machine tool spindle to produce high speed rotation, and then through the milling head (or drill) along the edge of the workpiece will break the material, so that the workpiece can be formed or separated. This processing method due to the high-speed rotation of the tool caused by material damage, will produce a lot of dust in the processing area, while the high-speed rotation of the tool will make the workpiece surface burr. In addition, the effect of the lateral force of the spindle will cause temporary deformation of the workpiece material, thus affecting the shape quality and dimensional accuracy of the workpiece.

Finally, the method of fixing the workpiece to the workbench (equivalent to the clamping of metal workpiece) is often complicated by the use of chemical adhesives with strong cohesion due to the influence of spindle lateral forces. After processing, the process of removing adhesive is not only time-consuming, polluting the environment, but also can damage the workpiece that has been processed, leading to the rise in cost.

The ultrasonic cutting process is completely different. First of all, the key of ultrasonic cutting lies in "cutting", rather than the "cutting" of unconventional machine tools. Figuratively speaking, ultrasonic cutting is like using scissors to cut paper or cutting leather with a knife, without producing debris of the workpiece. Compared with conventional "cutting and cutting", ultrasonic cutting head can apply 20 ~ 30kHz vibration energy on scissors or knives to help open the molecular structure inside the material. Precisely because of this feature, the cutting tool can cut the material more easily during the cutting process, the cutting speed is much higher than the traditional milling process.

Secondly, because there is no problem to break the material, ultrasonic cutting will not produce dust, can avoid the installation of dust, dust removal equipment.

Third, ultrasonic cutting due to greatly reduce the lateral feed force, so in addition to not produce workpiece deformation, but also make the material card fixed very simple and convenient, only with vacuum adsorption or adhesive paper bonding. Therefore, the use of ultrasonic cutting technology can win users higher cutting efficiency, more perfect workpiece quality, lower processing cost and more excellent environmental protection effect.

2, Compared with the traditional mechanical tool in the processing of fiber materials

The traditional cutting methods of fiber materials include disc cutting, broach cutting and reciprocating cutting tools. Common disadvantages include:

(1) low cutting efficiency. Due to the traditional mechanical cutting tool in the process of pulling, rolling or reciprocating motion of the tool to disconnect the workpiece material, cutting speed is limited.

(2) Poor cutting accuracy. The lateral force in cutting tool cutting process is bigger, cause workpiece material to be out of shape easily, affect form surface accuracy directly, in addition a few tiny form surface also is not easy to process.

(3) Stick knife. The friction and thermal effect of traditional machining in the process of cutting often appear the phenomenon of sticking knife, resulting in the reduction of cutting quality.

(4) the cutter and cutting head loss. Due to the mechanical friction in the cutting process, the loss of the tool and the cutting head are very large, so the life is limited, the cost of maintenance is also high.

(5) Cutting restriction. The biggest weakness of traditional cutting method is unable to process some high toughness materials. The most typical case is that the traditional cutting method is not competent for the processing of Kevlar materials and the current rise of dry UD materials.

Ultrasonic cutting bed can load the ultrasonic vibration energy on the cutting tool, according to the basic principle of ultrasonic cutting, the energy can effectively break the fiber material boundary, so that the traditional cutting method encountered difficulties solved, can achieve multi-layer fiber and prepreg cutting in the production process. Ultrasonic cutting is also more effective in cutting kevlar and dry UD materials.