使用超聲波清洗模具可節(jié)省時(shí)間，并且比其他技術(shù)更好地完成了模具清洗。塑料注射模具必須定期清潔，以從表面清除所有燃燒的沉積物，以及通風(fēng)口中的殘留塑料，而不會(huì)損壞模具。

超聲波方法的最大收益是節(jié)省時(shí)間。惠勒說(shuō)：“手洗模具是耗時(shí)的，而且很少有區(qū)域難以達(dá)到。” “坦白說(shuō)，沒有辦法手動(dòng)清潔，無(wú)論如何仔細(xì)地應(yīng)用，都可以訪問復(fù)雜的形狀，通風(fēng)口，傾倒和其他模具表面配置。我們使用生物可降解的水溶性液體進(jìn)入裂縫和縫隙以松開碎屑和氣體。這使我的工作更容易。超聲波設(shè)備的工作時(shí)間平均約為30分鐘，這個(gè)任務(wù)可能需要幾個(gè)小時(shí)才能手動(dòng)完成。

使用超聲波方法還可以使模具技術(shù)人員進(jìn)行多任務(wù)。“雖然一些模具部件在超聲波罐中，但它們可以清潔模具底座，這樣可以使工作更快速，從而產(chǎn)生更高質(zhì)量的零件。”

除了頻率和脈沖之外，操作面板允許操作員設(shè)置清潔周期時(shí)間和溶液溫度。顯示設(shè)置和實(shí)際參數(shù)。當(dāng)達(dá)到設(shè)定溫度時(shí)，本機(jī)將啟動(dòng)，并可在12小時(shí)內(nèi)自動(dòng)關(guān)閉或溶液溫度達(dá)到90°C，連續(xù)運(yùn)行.PAM注塑成型選擇絕緣罐蓋，以清潔循環(huán)中的噪音，并減少清洗液蒸發(fā)。

“更長(zhǎng)的注射模具壽命取決于不僅要保持清潔，而且可以通過(guò)維持表面光潔度的規(guī)格來(lái)延長(zhǎng)使用壽命。

清洗前

清洗后

SZFEAT  has found that cleaning molds using the ultrasonic method saves time and does a much better job of mold cleaning than other techniques. Plastic injection molds must be cleaned on a regular basis to remove all burned-on deposits from the surface as well as residual plastic in vents without damaging the tooling. The image below shows a mold before (left) and after ultrasonic cleaning.

SZFEAT Injection Molding molds a variety of products for the automotive, household, and lawn and garden markets, among others, using 20 presses ranging in size up to 950 tons. “A lot of our molds have interchangeable modules to make different part numbers. We can pop the modules out, take the back off, loosen the inserts and put the mold in the tank, so we can thoroughly clean around the inserts, and loosen the deposits and gas,” Roger Wheeler, Tooling Manager at PAM Injection Molding, told PlasticsToday.

“For some molds, we have to take out each individual insert and clean it. Some are easier to clean than others. The materials we’re running and the type of mold determine how far we have to take it apart to put it in the ultrasonic cleaner,” says Wheeler.

Time saving is the biggest benefit of the ultrasonic method, according to Wheeler. “Hand cleaning a mold is time consuming, and there are little areas that are tough to reach,” said Wheeler. “Frankly there’s no way that manual cleaning, not matter how carefully applied, can access complex shapes, vents, dumps and other mold surface configurations. We use a bio-degradable, water-soluble fluid that gets into the cracks and crevices to loosen the debris and gas. It makes my job a lot easier. The ultrasonic equipment does the job in about 30 minutes average—a task that could take hours if done manually.”

Wheeler adds that using the ultrasonic method also allows mold technicians to multi-task. “While some mold components are in the ultrasonic tank, they can clean the mold base, which makes the job faster and results in higher quality parts.”

SZFAEAT Injection Molding uses the Elmasonic X-tra Basic 550 industrial ultrasonic cleaner with a 15-gallon tank. “We often take in molds from other molders and find that these molds are in poor condition,” said Wheeler. “We take them apart and clean them thoroughly before putting them in our presses to ensure good part quality.”

Ultrasonic cleaning uses a process called cavitation—the implosion of billions of microscopic air bubbles—against surfaces immersed in a cleaning solution. Bubbles are created by generator-powered transducers bonded to the underside of a stainless-steel tank.

When excited, the transducers vibrate at ultrasonic frequencies measured in kilohertz (kHz) per second. This causes the tank bottom to act as a membrane creating the bubbles.

SZFEAT Injection Molding appreciates that the Elmasonic X-tra Basic 550 allows users to select a 25- or 45-kHz ultrasonic frequency based on the extent and tenacity of burned-on plastic residues. “For really tough deposits, our operators can activate what is called the ‘pulse mode’ that sends a more powerful blast of cleaning action into the bath,” Wheeler said. “Pulse is also activated to de-gas fresh ultrasonic cleaning solutions in order to quickly remove cavitation-inhibiting trapped air.”

In addition to frequency and pulse, the operating panel allows operators to set the cleaning cycle time and solution temperature. Set and actual parameters are displayed. The unit will start when the set temperature is reached and can operate continuously with auto shut-off at 12 hours or if the solutions temperature reaches 90° C. PAM Injection Molding selected an insulated tank lid to muffle noise during the cleaning cycle and to reduce cleaning solution evaporation.

“Longer injection mold life depends on not only keeping them clean but conducting mold-cleaning operations in such a way that extends their life by maintaining surface finish specifications,” Wheeler added.