Ultrasonic Metal Cutting Machines

Rotary Metal Saws

• Traditionally most metal is cut using a rotary blade on a heavy table. This type of saw is standard for cutting thin metals used for housing or other construction. However, this type of saw blade is of a similar material to what is being cut, so the blade quickly wears down or is damaged. With the application of ultrasonic vibrations the blade can be used for a longer period of time. The vibrations reduce the friction and wear on the blade. However; metal does not work as well with ultrasonic vibrations as do other types of material.

Stone Saws

• Some metal-cutting saws, such as the angle grinder, use a rock-based blade to grind away or cut the metal. These blades can be used on a small scale for noncommercial projects, or larger blades are used commercially to quickly cut metal. The disadvantage of this type of cutting is that the blades are weaker than the metal and often need to be replaced. With ultrasonic vibrations, stone saws decrease particle loss so that they last longer as well as cut more smoothly without damage.

Diamond Blades

• Diamond is one of the hardest substances on the planet and is therefore highly suitable to use as a cutting mechanism. The diamond's strength and durability are enough to withstand even the hardest of steels. However, diamond breaks down into graphite at around 400 degrees Fahrenheit when in contact with certain metals such as titanium, nickel and cobalt. This means that even a normal diamond blade could suffer immense wear and tear during the process of cutting steel. Using ultrasonic vibration, the diamond tool tip can be transformed into a more effective and longer lasting cutting instrument. Ultrasonic diamond tool tips have the ability to cut polished and microhardened steel while retaining a reasonable tool life span.

How It Works

• Ultrasonic vibration can cause a process known as cavitation. In a liquid, this process is evident as the rise of gases from the substance. Cavitation works when the ultrasonic vibration lowers the boiling point of the material in question and therefore lowers the temperature. In a diamond cutting tool, cavitation allows the tip to be immensely cooled during the cutting process so that it avoids graphitization.