超音波輔助異種塑膠材料旋熔複合加工之分析

Ultrasound-Assisted Spin Welding Processing Machine to Analyze and Discuss the Combined Processing of the Dissimilar Plastic Materials

莊佳翰(Chia- Han Chuang)

指導教授 ： 許坤明

國立虎尾科技大學/工程學院/創意工程與精密科技研究所/碩士(2011年)

https://doi.org/10.6827/NFU.2011.00064

摘要

本論文主要利用超音波輔助旋熔加工機對異種塑膠材料進行複合加工的分析探討，藉以改善傳統上超音波熔接異種材料時接合性的不足、提高拉應力、改善表面品質和提高加工效率。使用一種結合超音波熔接及旋轉熔接且具有高速馬達的整合型加工機，主要原理係以高速旋轉兩工件，使導能角頂部摩擦產生高溫，當熱塑性材料達到熱變形溫度時，施加適當壓力於另一種材料上，表面會在半融熔狀態下達到熔接，同時再以超音波振盪子激振，以及聲波焊頭的放大位移效應，使接觸摩擦面達到溫度上升的效果，增進熱塑性材料的接合效果。
此外，超音波輔助異種材料旋熔的加工效益，主要來自於聲波焊頭之設計，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階梯型聲波焊頭的分析與設計。以廠商所提供之階梯型聲波焊頭做為尺寸基礎，設計及製造出最佳尺寸之理論焊頭，分別利用ANSYS進行振動模態分析，而獲得其自然頻率，進而分析比較。最後利用頻率量測儀對理論焊頭進行實際量測，結果顯示，使用ANSYS理論後的聲波焊頭，在進行實際模態量測時，其結果與使用ANSYS進行模態分析所得的結果相近。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。
最後使用熱塑性塑材PVC及PP進行加工測試，實驗後得到之試件藉由拉伸試驗求得抗拉強度，並利用田口方法，找出最佳製程參數及加工因子之貢獻率，並經由預測值與確認實驗比對理論值，可發現誤差值在2%以內。而影響熔接成果主要的因素為超音波的熔接壓力以及硬化時間兩種因素。

關鍵字

超音波與旋轉熔接 ； 聲波焊頭 ； 模態分析 ； 有限元素法 ； 田口法

並列摘要

This study used ultrasound-assisted spin welding processing machine to analyze and discuss the combined processing of the dissimilar plastic materials, in order to improve the tensile stress, surface quality, and processing efficiency by enhancing the insufficiency of the connectivity when heterogeneous materials are welded by the ultrasound. An integrated processing machine combining the ultrasonic welding and spin welding and equipped with the high-speed motor was used. Its main principle was to enable the conducting angle of the two work pieces in high-speed spinning to generate high temperature on the top through friction. When the thermoplastic materials reached the thermal deformation temperature, an adequate pressure was exerted on the other materials, so that the surfaces would be welded under the semi-molten state. Meanwhile, an ultrasonic oscillator was used for fierce oscillation, in combination with the amplified displacement effect of the sound wave welding head, the temperature of the contact friction face would rise, which would enhance the connectivity effect of the thermoplastic materials.
The processing efficiency of the ultrasound-assisted spin welding of the dissimilar materials was from the design of the sound wave welding head, the quality of which would affect the processing effect. Therefore, this study used ANSYS finite element analysis software to analyze and design the step sound wave welding head, based on the data provided by the manufacturers. Theoretic welding head with the optimal dimension was designed and manufactured taking the step sound wave welding head provided by the manufacturers as the dimension basis. ANSYS was used for oscillation modal analysis, so as to obtain the natural frequency for further analysis and comparison. The frequency measuring instrument was used for the actual measuring of the theoretic welding head. The results showed that, for the sound wave welding head after using the ANSYS theory, the outcome of the actual modal measuring were similar to those obtained through the modal analysis by ANSYS. During welding head processing, the trial and error time for dimension modification could be saved greatly and the efficiency of the welding head could be promoted.
The thermoplastic materials PVC and PP were used for processing test. The tensile strength of the test pieces after the experiment was obtained by the tension test. The optimal processing parameters and the contribution rates of the processing factors were determined by Taguchi method. The predicted value and the theoretical value were compared by confirmatory test, and the error rate was within 2%. The main factors to affect the welding results were the welding pressure and the hardening time of the ultrasound.

並列關鍵字

ultrasound and spin welding ； sound wave welding head ； modal analysis ； infinite element method ； Taguchi method

參考文獻

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