- 學位論文
結合切割-滾花-熔接之超音波複合加工機研發及其加工參數研究
The Fabrication of Ultrasonic Machine Composite with Cuting-Rolling-Welding and Its Processing Parameters
摘要
本文利用超音波之技術來應用於布料加工，並研發出同時具有剪切、滾花和熔接之超音波複合加工機。此機台主要利用超音波傳動子連接聲波焊頭，透過聲波焊頭之放大位移效應，將此振動能量傳遞到加工布料上，在配合花輪加壓下與布料間之切割面產生摩擦，而瞬間產生高溫，從而完成切割面呈現熔融狀態，達到超音波熔切之效果。 此外，超音波熔切加工效率，重點在於聲波焊頭之設計，聲波焊頭之優劣將會影響到加工效果，因此本論文使用ANSYS有限元素分析之軟體，針對廠商所提供的資料進行聲波焊頭的分析與設計，先對複合型聲波焊頭進行收斂性分析，找出最佳的網格數目後，再以廠商所提供聲波焊頭與ANSYS最佳化聲波焊頭，進行模態分析，藉以證明使用ANSYS最佳化設計出的聲波焊頭具有較佳熔切效果。最後利用頻率量測儀對最佳化後聲波焊頭進行實際量測，結果顯示，測得之頻率為19.8 kHz且接近於超音波產生器所產生之20kHz，並符合於模擬分析值。在焊頭加工上也能大幅節省尺寸修正的試誤時間，並能提升焊頭之效能。 最後使用此機台來進行加工測試，對不織布（Nylon）來進行熔切加工，實驗後之試件藉由光學顯微鏡觀察其熔切面之表面結構情形，再利用田口方法，找出最佳製程參數及加工因子之貢獻率，以提升加工之品質。
並列摘要
This study used ultrasound technology on fabric processing, and developed the ultrasound compound processing machines with cutting, knurling and welding functions. The machines use the ultrasound driving motor to connect with the sound wave welding head, transfer the vibration energy to the processed cloth by the amplified displacement effect of the sound wave welding head, generate friction on the cutting faces between the cloths in combination with the floral whorl compression to generate high temperature instantly, thus to make the cutting faces present a molten state and achieve the ultrasound fusion cutting effect. The key of the processing efficiency of the ultrasound fusion cutting is the design of the sound wave welding head, and its quality affects the processing effect. This study used ANSYS finite element analysis software to analyze and design the sound wave welding head based on the data provided by the manufacturers. Convergence analysis was conducted on the composite sound wave welding head to determine the optimal mesh number, and carry out modal analysis on the wave heads provided by the manufacturers and optimized through ANSYS. The results proved that the sound wave welding head optimized through ANSYS have better fusion cutting effect. The frequency measuring instrument was used for the actual measurement of the optimized sound wave welding head. The measured frequency was 19.8 kHz, which was closer to the frequency (20 kHz) generated by the ultrasound generator and conformed to the simulation analysis value. As for the welding head processing, the trial and error time for dimension modification could be saved greatly and the efficiency of the welding head could be improved. This machine set was used for processing test to carry out fusion cutting processing on the nonwoven fabrics (Nylon). The surface structure of the fusion cutting face of the test piece after the experiment was observed by the optical microscope. The optimal processing parameters and the contribution rates of the processing factors were determined by Taguchi method, so as to improve the processing quality.