Ultrasonic Cutting Machine
What is Ultrasonic Cutting Machine?
Ultrasonic cutting machines are machines where the cutting blade or knife vibrates at a very high frequency. The vibration frequency is actually even higher than the frequency of sound that can be heard by the human ear. In humans, this is limited to frequencies in the range of approximately 16–20,000 Hz. Anything above 20,000 Hz is considered ultrasound. And it is at this frequency that ultrasonic cutting machines operate.
Why Choose Us?
Application Areas
Ultrasonic cutting is a technology that achieves precision machining of materials through high-frequency mechanical vibration, mainly applied to the lightweight requirements of aerospace equipment for precision machining of glass fiber and carbon fiber composite components; Suitable for non-destructive cutting of thermal sensitive foods such as cakes and chocolates in the food industry; The textile manufacturing industry of edge anti shedding cutting of non-woven fabrics, meltblown fabrics and other materials; Applied in the electronic component industry for stress free cutting of precision electronic materials such as flexible circuit boards (FPC) and graphene films.
Sales Marke
Our products are sold in many countries, including the United States, Canada, Russia, South Korea, Indonesia, Colombia, Germany, Poland, South Africa, the Netherlands, Hungary, France, Vietnam, Bulgaria, the United Kingdom, Mexico, and the United Arab Emirates and so on. Our main customers are agents experienced in ultrasound technology and end users.
Our Products
According to different cutting applications, FUNSONIC offers 20Khz, 30Khz, 40Khz handheld and machine mounted cutting knives, equipped with replaceable blades of different widths to meet the needs of various industries.
Our Team
Hangzhou FUNSONIC Ultrasonic Company was founded in 2018, led by multiple experts with over 10 years of practical experience in the field of high-power ultrasonic. The team members are mainly born in the 1980s and 1990s, all of whom have a college degree or above. Has strong competitiveness and challenge, used for innovation, responsibility, and accountability.
Advantages of Ultrasonic Cutting Machine
Precision Cutting
Ultrasonic cutting machines utilize high-frequency vibrations to create clean and precise cuts. The vibrations create a rapid oscillating motion in the cutting tool, resulting in precise and consistent cuts, even in intricate or complex patterns. This level of precision is particularly beneficial when working with delicate or sensitive materials.
Non-contact Cutting
Ultrasonic cutting is a non-contact method, which means the cutting tool does not come into direct contact with the material being cut. Instead, the ultrasonic vibrations create a high-energy cutting action that cleanly slices through the material without exerting excessive pressure. This non-contact nature of cutting helps prevent damage to the material, especially for fragile or thin materials that could be easily deformed or crushed by traditional cutting methods.
Reduced Friction and Heat
Ultrasonic cutting generates significantly less friction and heat compared to conventional cutting techniques. The rapid oscillating motion of the cutting tool reduces the resistance encountered during cutting, resulting in minimal heat buildup. This is particularly advantageous when working with thermoplastic materials, as it helps prevent melting, warping, or damage caused by excessive heat.
Versatility in Material Compatibility
Ultrasonic cutting machines can handle a wide range of materials, including plastics, foams, fabrics, composites, rubber, and even certain types of food products. This versatility makes them suitable for various manufacturing industries such as automotive, aerospace, textiles, packaging, and food processing. The ability to cut different materials effectively streamlines production processes and enhances operational efficiency.
Enhanced Efficiency and Productivity
The precision and speed of ultrasonic cutting machines contribute to increased efficiency and productivity in manufacturing. The high-frequency vibrations allow for rapid cutting speeds, reducing production time. Additionally, the clean cuts produced by ultrasonic cutting often eliminate or minimize the need for secondary finishing operations, saving additional time and resources.
Reduced Maintenance and Tooling Costs
Ultrasonic cutting machines typically have long tool life due to minimal wear and tear during operation. The non-contact cutting method reduces the wear on the cutting tools, resulting in extended tool life and reduced maintenance requirements. This can lead to cost savings in terms of tooling replacement and maintenance expenses over time.
Clean and Sealed Edges
Ultrasonic cutting machines create clean-cut edges that are often sealed during the cutting process. The high-frequency vibrations melt and fuse the edges of thermoplastic materials, creating a sealed edge that helps prevent fraying or unraveling. This sealing effect is particularly advantageous for fabrics, textiles, and synthetic materials where edge integrity is crucial.
Application of Ultrasonic Cutting Machine
Food Industry
Ultrasound cutting is used to cut various food products, including cakes, pastries, cheeses, and chocolates. It ensures precise portioning, clean cuts, and minimal product deformation.
Textile Industry
Ultrasonic cutting is employed for cutting and sealing synthetic fabrics and textiles, preventing fraying and unraveling of edges.
Plastics and Composites
Ultrasound cutting is used for cutting and trimming plastic materials, composites, and films, providing precision and clean edges.
Medical Applications
In the medical field, ultrasound-based cutting is used for delicate procedures, such as ophthalmic surgeries and tissue dissection, where precision and minimal tissue damage are critical.
Packaging
Ultrasound cutting is utilized for cutting and sealing packaging materials, ensuring airtight and tamper-evident seals.
Manufacturing
Ultrasound cutting is used in various manufacturing processes, including trimming excess material from molded parts, cutting gaskets, and precision cutting in electronics manufacturing.
Components of Ultrasonic Cutting Machine
Ultrasonic Generators
Ultrasonic Generator utilizes the 110 V AC or 220 V AC power supply electricity and turns it into a high voltage, high-frequency electricity signal. This signal is then fed to the transducers.
Ultrasonic Transducer
The ultrasonic transducer works as an ultrasonic converter. Its purpose is to take the high-frequency electrical signal and convert it into a mechanical high-frequency motion. It utilizes piezoelectric ceramic discs that expand on the application of electricity. Transducers are completely sealed so as to avoid contact of electrical parts with water during washing.
Ultrasonic Booster
The purpose of an ultrasonic booster is to fine-tune the mechanical frequency obtained by the transducer. It also acts as a stationary intermediatory where the cutting tool can be clamped. Boosters are generally a one-piece part made of Titanium metal.
Cutting Tool
The cutting tool is also called the blade, cutting horn, or sonotrode. This tool vibrates on the high frequency provided by the booster. The most common material for the cutting tool design is Titanium since Titanium is very resonant and has high longevity.
Material Handling Equipment
Material handling equipment controls the movement of the food relative to the cutter or moves the cutter relative to the food. A good handling system is important to create precise cuts at the right location.
Working principle
The working principle of ultrasonic cutting machine is completely different from traditional cutting machine. It uses the energy of ultrasonic, to melt the local heating of the material to be cut, so as to achieve the purpose of cutting the material. Therefore, ultrasonic cutting does not require a sharp edge. Nor does it require a lot of pressure, so that it will not cause the edge of the cut material to collapse and damage. At the same time, due to the ultrasonic vibration of the cutting knife. The friction resistance is very small, and the cutting material is not easy to stick to the blade. It is especially suitable for cutting viscous and elastic materials, frozen materials (such as food, rubber, etc.) or objects that are inconvenient to pressurize. Ultrasonic cutting also has a great advantage, that is, while cutting, the cutting part has a fusion effect. The edges of the cutting part are intact to prevent loose tissues of the cutting material (such as flashing of textile materials). The use of ultrasonic cutting machine can also be expanded, such as digging holes, shoveling, scraping paint, carving, cutting, etc.
Working Process
The ultrasonic cutting machine operates through a combination of key components. It comprises a “transducer” responsible for generating vibration and an “oscillator” that propels the transducer. Within the transducer, a piezoelectric element is employed. When voltage is applied, this element displaces the transducer marginally, typically by a few micrometers. The application of voltage at intervals produces vibration. Objects possess unique frequencies that render them stable and easily resonant. By applying an external force that matches this special frequency, a minor force can yield substantial vibration. This phenomenon is termed resonance. In the ultrasonic cutting machine, the piezoelectric element generates a force that resonates through the entire body, from the transducer to the blade tip, resulting in substantial vibration at the tip. The oscillator intermittently provides voltage to resonate and drive the transducer. Employing a component known as the horn, which tapers the cross-sectional area from the piezoelectric element to the blade tip, augments the vibration significantly.
What Requirements Can I Meet with Ultrasonic Cutting Machine Technology?
The ultrasonic blade produces smooth, reproducible cuts in all kinds of applications – from cutting films made of PE, PP or PVC to slicing cheese or portioning vanilla slices.
Whether your product is a cream cake or a plastic component, ultrasonic cutting machine won’t cause deformation.
Ultrasonic cutting machine is ideal for temperature-sensitive materials, as the cold ultrasonic blade won’t cause any heat damage. Chocolate bars might melt in your hands – but they’ll remain intact during ultrasonic cutting machine.
With ultrasonic technology, the cycle times for cutting food products, textiles and plastics are exceptionally short. Fast, continuous cutting is also easy to achieve.
Because of the way ultrasonic cutting machine works, the technique seals the edges of technical textiles, non-wovens and fabrics while simultaneously creating a clean and precise cut edge, eliminating the risk of fraying.
The maintenance intervals for cleaning ultrasonic blades are very long. Materials don’t stick to the blade like they would on a kitchen knife; the oscillating motion shakes off any residues during the cutting process, significantly reducing downtime for blade and surface cleaning.
The technological principle of ultrasonic cutting machine makes textile cutting a clean and easy process, with minimal levels of dust.
How Does an Ultrasonic Cutting Machine Cut Cakes?
Ultrasonic Transducer
The key component of the ultrasonic cake cutter is the ultrasonic transducer. This transducer converts electrical energy into high-frequency mechanical vibrations, typically in the range of 20,000 to 40,000 Hertz (cycles per second).
Horn (Sonotrode)
The ultrasonic transducer is connected to a horn or sonotrode, a metal tool designed to amplify and transmit the ultrasonic vibrations to the cutting blade. The horn's shape and dimensions are specifically designed for cake cutting applications.
Cake Placement
The cake to be cut is positioned beneath the cutting blade, which is attached to the horn. The cake can be of various sizes and types, including sheet cakes, layered cakes, and specialty cakes.
Pressure and Ultrasonic Energy
To initiate the cutting process, the horn applies gentle pressure to the cake's surface, ensuring proper contact between the blade and the cake. Simultaneously, the ultrasonic transducer generates high-frequency vibrations in the horn.
Cutting Action
As the ultrasonic vibrations are transmitted to the cutting blade, they create a rapid, reciprocating motion. This motion causes the blade to oscillate back and forth at ultrasonic frequencies. The blade's rapid movement, combined with the pressure applied to the cake, results in precise cutting.
Clean and Precise Cuts
The ultrasonic vibrations generate localized heat at the cutting point, which softens or melts the cake material as it's being cut. This localized heat, along with the blade's motion, creates a clean and precise cut, leaving smooth edges with minimal crumbs or debris.
Cooling and Solidification
After the ultrasonic energy is turned off, the melted cake material cools and solidifies rapidly, leaving behind a well-defined and neatly cut cake slice.
Repeatable Cutting
The ultrasonic cake cutter can be programmed to cut cakes into specific shapes and sizes with a high degree of repeatability, ensuring consistent portion sizes and presentation.
Traditional cutting utilizes a knife with a sharp edge that is pressed against the product being cut. It requires a relatively sharp cutting tool and a large pressure, which will cause deformation to the product and affect its cutting surface quality and dimensional accuracy. The cutting effect is not good for soft, brittle, and elastic materials, and it is more difficult for viscous and hard materials.
Ultrasonic cutting machine uses ultrasonic vibration for cutting. The distinctive feature is that it does not use traditional cutting edges. The cutting tool is usually a dunt blade made of titanium alloy. The ultrasonic cutting machine reduces the pressure on the product to be cut through high-frequency vibration, generating a flat and smooth cut surface without causing deformation or heat damage to the product. At the same time, this high-frequency vibration makes it difficult for the product to stick to the blade. And the cutting part has a fusion effect to reduce the loose organization of the cut item (such as slags and crumbles). These characteristics of ultrasonic are especially effective for cutting frozen, viscous, hard, and brittle products.
Traditional cutting machines simply rely on the mechanical motion of knives to cut the product, and the mechanical friction force is relatively large during the cutting process, which makes them have low cutting efficiency, large blade loss, short life, and troublesome maintenance.
Ultrasonic cutting machines use high-frequency wave vibration to process food quickly, and the efficiency has been greatly improved. The non-stick properties eliminate downtime for cutting blade cleaning. Moreover, the ultrasonic cutting machine is more durable and reduces production costs.
Quality cutting effect. It is the distinctive feature that make the ultrasonic cutting machine different from other cutting machines. And it is the reason for wholesale bakeries to choose an ultrasonic cutting machine.
Easy to use. It important to choose a cutter that is easy to operate especially for automatic machines. Complex procedure is difficult for workers to operate.
Multi-function. A good cutting machine must be multifunctional, it can not only cut one kind of products, but also can cut other products in different ingredients, temperatures, sizes and shapes.
Long service life. A good ultrasonic cutting machine should have a long lifespan with low-cost maintenance.
Spare parts support. It is important that you can easily get the spare parts at reasonable prices.
Professional technology support. For an ultrasonic cutting machine, professional and prompt technical support is very important.
Maintenance Tips for Ultrasonic Cutting Machines to Prolong Lifespan
Keep the machine clean
Regularly clean the machine to prevent dust, debris, and other contaminants from building up. Use a soft cloth and mild cleaning solution to wipe down the machine and remove any residue.
Inspect the components
Check the cutting blade, horn, and other components regularly to ensure they are in good condition. If any components are damaged or worn out, replace them promptly to avoid further damage.
Lubricate moving parts
Ultrasonic cutting machines have many moving parts that require lubrication to function properly. Use a high-quality lubricant to keep these parts running smoothly and prevent damage from friction.
Use proper settings
Make sure you are using the correct settings for the material you are cutting. Using the wrong settings can cause excessive wear and tear on the machine and reduce its lifespan.
Perform regular maintenance
Follow the manufacturer's recommended maintenance schedule to keep the machine running smoothly. This may include cleaning, lubrication, and component replacement.
Store the machine properly
When not in use, store the machine in a dry, clean area. Cover it with a protective cover to prevent dust and debris from accumulating.
Troubleshooting Common Problems with Ultrasonic Cutting Machines
Blade breakage
One of the most common problems with ultrasonic cutting machines is blade breakage. This can occur if the blade is worn out or if it comes into contact with a hard surface.
Solution: Replace the blade if it is worn out. Also, make sure that the blade is not being used to cut hard surfaces like metal or stone, which can cause it to break.
Uneven cuts
Another common issue is uneven cuts, where the machine is not cutting evenly across the material.
Solution: This can happen if the blade is not aligned properly or if the material is not flat. Check the alignment of the blade and make sure the material is flat before cutting.
Blade overheating
Overheating of the blade can lead to poor cutting performance and reduced blade life.
Solution: Check that the cooling system is working properly and that the blade is being lubricated sufficiently. You can also reduce the cutting speed or reduce the cutting force to prevent overheating.
Insufficient power output
If the machine is not cutting as expected, it may be due to insufficient power output.
Solution: Check the power supply and make sure that the machine is properly connected. You can also increase the power output, but make sure not to exceed the recommended limits for your machine.
Machine not working at all
If the machine is not working at all, it may be due to a variety of reasons such as faulty connections, malfunctioning components, or power supply issues.
Solution: Check all connections and make sure that all components are working properly. If you are unable to identify the issue, contact the manufacturer for assistance.
Our Certifications
Our Factory
FUNSONIC was established In 2018. It is composed of several engineers with more than 20 years of practical experience in the field of high-power ultrasound. FUNSONIC focus on the development and manufacture of ultrasonic equipment, such as ultrasonic spray coating machine,ultrasonic nozzle spray shaping machine, ultrasonic welding equipment, ultrasonic cutting equipment, ultrasonic liquid processing equipment, various kinds of ultrasonic core components. Also we will provide customized services according to the needs of our customers.
Ultimate FAQ Guide to Ultrasonic Cutting Machine
As one of the most professional ultrasonic cutting machine manufacturers and suppliers in China, we're featured by quality products and low price. Please rest assured to buy ultrasonic cutting machine for sale here from our factory. Also, customized service is available.
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