Evaluation and Characterization of Ultrasonic Cutting of Monofilament Nylon

Abstract

Nylon (polyamide) is a typical composite base material, but its low hardness, poor rigidity, and low dimensional stability easily lead to burrs, fractures, curling, and other problems after nylon end faces are processed by conventional techniques. To prevent these problems, this article conducted experimental research comparing ultrasonic and conventional cutting of monofilament nylon and used the controlled variable method to analyze the micromorphology after cutting at different speeds and tensions. A novel ratio was also derived to characterize the topographic quality, and the feasibility and advantages of ultrasonic cutting of nylon were verified by evaluating the nylon surface quality under different cutting conditions. Test results showed layering on the rear face of nylon with ultrasonic cutting as well as a morphology quality directly proportional to the feed speed of the tool and inversely proportional to the tensile force exerted on the material. The end face of nylon after ultrasonic cutting provided a ratio 2.9% lower than that obtained from conventional cutting as well as a roughness reduction of 31.3%. Compared with conventional cutting, the end face was preserved, and no large-area breakage or edge curling occurred when using ultrasonic cutting. Moreover, a force analysis theoretically confirmed the advantages of ultrasonic cutting.