What Is Ultrasonic Energy Bar Cutting Technology？

1. Principle of ultrasonic energy bar cutting

The core of ultrasonic energy bar cutting technology is to use the high-frequency vibration of ultrasound. Generally speaking, the frequency range of ultrasound is between 20kHz and 40kHz. In this technical system, the electrical energy is first converted into a high-frequency electrical energy signal through an ultrasonic generator. This high-frequency electrical energy signal is then transmitted to the transducer, which plays a vital role in converting the received high-frequency electrical energy into mechanical vibration in the vertical direction. In order to make the amplitude of this mechanical vibration meet the cutting requirements, the vibration amplitude needs to be amplified by an amplitude modulator. The amplified mechanical vibration is finally transmitted to the cutting die, which is the edge of the energy bar. At this time, the edge of the energy bar will produce tens of thousands of microscopic vibrations per second.

When the energy bar comes into contact with the material to be cut, the friction between the material molecules increases sharply under the action of high-frequency vibration, and this friction will produce an instantaneous temperature rise. Under the combined action of the pressure of the die itself and the energy generated by the high-frequency vibration, the part of the material to be cut will instantly soften or even melt, and its strength will also drop significantly. At this time, only a relatively small external force needs to be applied to easily destroy the bond between the material molecules, thereby achieving the melting and separation of the material and completing the cutting process.

2. Advantages of ultrasonic energy bar cutting

High cutting accuracy: Ultrasonic energy bar cutting can achieve very precise cutting effects. Due to its extremely high vibration frequency, the position and depth of the cut can be precisely controlled during the cutting process. Taking the processing of composite materials in the aerospace field as an example, for some parts with extremely high dimensional accuracy requirements, the use of ultrasonic energy bar cutting can control the error within a very small range, ensuring that the quality and performance of the parts meet strict standards. This high-precision cutting ability also plays an important role in the cutting of microelectronic components, and can meet the needs of the electronics industry for precision processing of tiny components.

Excellent incision quality: Unlike traditional cutting methods, the incision after ultrasonic energy bar cutting is very smooth and flat. When cutting food, such as cutting cakes, bread and other baked goods, it can neatly cut out various shapes and sizes without damaging the cake decoration or the texture of the bread, ensuring the beauty of the product. When cutting materials such as plastic sheets and textile fabrics, the incision will not have burrs, wire drawing, rough edges or de-threading. Moreover, when cutting thermoplastic materials, the heat generated during the cutting process will cause the material at the incision to melt locally, and then quickly cool and solidify, thus forming an effect similar to fusion sealing, which can prevent the loosening of the cut material tissue, which has obvious advantages in the cutting of plastic films, non-woven fabrics and other materials.

No thermal damage or low damage: In many cutting scenarios, thermal damage is an issue that needs to be focused on. Some traditional cutting methods, such as laser cutting and thermal cutting, will generate a lot of heat during the cutting process, which can easily lead to problems such as thermal deformation and thermal degradation of the cut material. The ultrasonic energy bar cutting technology generates relatively less heat during the cutting process. Taking the ultrasonic knife used in surgery (which can be regarded as a special ultrasonic energy bar) as an example, when it cuts tissue, it uses ultrasonic energy to coagulate and close small blood vessels, reducing intraoperative bleeding. At the same time, compared with traditional electric knives, it generates less heat, reducing the risk of thermal damage to surrounding normal tissues, and helping to improve the safety and effectiveness of the operation. When cutting some temperature-sensitive materials, such as some special electronic components and biomaterials, the low heat characteristics of ultrasonic energy bar cutting are particularly important, which can protect the original performance of the material to the greatest extent.

Widely applicable materials: Ultrasonic energy bar cutting technology has a wide range of material applicability. In the food industry, it can easily cut meat, cheese, pizza, energy bars and other foods, cut meat into uniform slices or blocks, reduce the loss of meat juice, and keep the meat fresh and nutritious; in the plastic processing industry, whether it is plastic sheets of different thicknesses, such as acrylic sheets, PVC sheets, or plastic films and plastic parts of complex shapes, they can all be cut with high precision; in the textile and clothing industry, ordinary cotton fabrics, silk, chemical fiber and other special fabrics, as well as leather, non-woven fabrics, etc. can be accurately cut; in addition, for other materials such as foam materials, composite materials (such as carbon fiber composite materials, glass fiber composite materials), ultrasonic energy bar cutting can also play a good cutting effect.

Improve production efficiency: Since the cutting speed of ultrasonic energy bars is relatively fast and the cutting process is relatively stable, it is not necessary to replace or trim the cutter as frequently as the traditional cutting method, so it can greatly improve production efficiency. In food processing enterprises, using ultrasonic energy bar cutting equipment to cut ham, sausage, etc. can complete a large number of cutting tasks in a short time and increase product output. In the large-scale production of industries such as plastic processing, textiles and clothing, the high efficiency of ultrasonic energy bar cutting technology can also bring significant economic benefits to enterprises and reduce production costs.