Affecting Factors and extension methods of ultrasonic molds

Ultrasonic molds are deformed, cracked, stuck, cracked due to wear, erosion, corrosion and thermal fatigue. After forming burrs, flash, peeling, scratches,roughness and dimensional deviation on the castings, The number of parts that can be processed before being scrapped is called the service life of the ultrasonic mold.There are many factors affecting the life of ultrasonic molds, both external and internal. External factors refer to the external environment during mold operation, including working conditions, equipment conditions, maintenance and maintenance during use, materials of processed parts, wall thickness , size, shape, etc. Pzt ceramic ring means metallurgical quality of the mold material itself, the machining process specification, a thermal processing system, including rough forging and heat treatment and a reasonable, advanced process design and configuration of the mold with the precise accuracy of the like.If we handle all the above mentioned aspects properly, the durability of the ultrasonic mold will be guaranteed.

The life of a set of ultrasonic molds is determined by two aspects:

1.Materials and materials: immersible ultrasonic transducer requires metal materials to have good flexibility (small mechanical loss during sonic transmission), so the most commonly used materials are aluminum alloys and titanium alloys. The material is one of the main reasons for ensuring the life of the ultrasonic mold in the welding product, and the process of completing the mold is complicated. Therefore, not only the mold engineer design must carefully select the material, but also need to understand the material that the product requires to avoid inadvertently affect its timeliness and quality.

2.Process: Product requirements: Determine the service life and wear rate of the mold, and thus decide which metal to use. 2. Shape of the product: What kind of welding process is used to set the size of the mold, the pressure transmission area, the deformation that may occur when the product is fused, and how much power and function is required. Whether it is possible to complete the work in one weld. 3, the plastic nature of the product: determine the working amplitude of the mold, that work should accept the ultrasonic energy, the form of the energy line, location, size. How should the contact position be designed when different plastic combinations are used?

The basic way to improve the life of the mold: 1. High-quality steel; the fracture of the mold blank during forging or the process defects during quenching and the reduction of its load-bearing capacity during use are all related to the metallurgical quality of the steel; 2. Using advanced blanks Forging process; uniform deformation during forging, easy to forge, make carbide finely crushed, and improve the overall structure; 3. Preliminary inspection of good mold material, from the production point of view, for the convenience and speed, the spark identification method can be used; 4. Carefully design the structure of the mold; the content of the mold design is extremely rich, and it can start from the structural process analysis of the casting; 5. Adopt the best mold heat treatment specification; the mold material of high power ultrasonic transducer must have high heat strength and tempering stability. In this way, it is possible to obtain high thermal fatigue resistance and wear resistance; 6. High-energy density surface strengthening treatment of the mold; high energy density surface strengthening is the application of extremely high energy on the surface of the material, causing physical and chemical changes to achieve strengthening purpose. 7. Establish a comprehensive quality management system; the implementation of total quality management in the production and use of ultrasonic molds is an important means to mold the quality of information.