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.
