Ultrasonic application:
The use of industrial ultrasonic cleaner for routine injection mold maintenance has been effectively employed for many years. It provides a number of benefits not achievable using more traditional methods. As it is a non-contact process, mold detail is not damaged during cleaning. Critical tolerances can be preserved, thereby extending mold life.
The higher levels of cleanliness attained using ultrasonic cleaning also results in better releases and longer runs while improving productivity and minimizing scrap.
The penetrating nature of ultrasonic cleaning minimizes the requirement for mold dis-assembly and removes residual polymer and releases from mechanically active mold components thus extending their life. It can also remove buildups from internal cooling ports and channels, thereby improving polymer flows.
The use of mould and die cleaning system developed by us is a high-tech, low-labour method for cleaning injection moulds and dies. The ultrasonic cleaning removes carbonization, mould release, gassing, flashing, and other residues from moulds and dies in as little as 15-20 minutes.
How much ultrasonic power does your cleaning tank require?
The right amount of ultrasonic energy (usually expressed in watts/gallon) depends on the size of the cleaning bath and the difficulty of the cleaning requirement. Tanks in the one- to two-gallon range often provide up to 90 watts per gallon of ultrasonic power, plenty for most jobs, even cleaning out the ultra-fine passages of fuel injector nozzles.
"Achieving the same cleaning effect in larger tanks requires less energy density," Pedeflous noted. "Excellent cleaning has been demonstrated in tanks having 50 gallons capacity with only 25-30 watts per gallon. The more difficult the application, the greater energy density is required for effective cleaning."
On the other hand, too much ultrasonic power may result in cavitation erosion occurring on delicate or highly polished parts that are near the transducer-radiating surface. Cavitation is the formation and collapse of low-pressure bubbles that can pit the surface of metals. Aluminum, copper, brass and other soft metals are especially susceptible to cavitation erosion.
