超音波輔助鑲嵌機之研發及其加工參數之研究

This study of Ultrasonic-Aided Inserting Machine and Its Processing Parameters

趙原伯(Yuan-Po Chao)

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(2010年)

摘要

本文利用使用超音波熔接之技術來應用於鑲嵌加工，並研發出超音波輔助鑲嵌機。此機台主要是利用超音波振動子激振，透過聲波焊頭之放大位移，把此振動能量傳至金屬嵌件上，金屬嵌件與熱塑性材料間之接觸面將有劇烈摩擦，而瞬間產生高溫，當熱塑性材料達到熱變形之溫度時，局部塑膠會呈現半融熔狀態，並同時施加壓力於嵌件上，而驅導入熱塑性材料內，熔化之塑膠則會流入金屬嵌件外表之咬花齒紋與底槽內，達到超音波鑲嵌之效果。
此外，超音波鑲嵌加工效率，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，進行鑲嵌之聲波焊頭分析與設計。以廠商所提供之錐形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，近而分析比較。最後利用頻率量測儀對理論焊頭進行實際量測，結果顯示，測得之頻率為14.8 kHz且接近於超音波產生器所產生之15kHz，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，對市面上常見之塑膠材料: PVC及ABS來進行鑲嵌加工，實驗後之試件藉由拉伸試驗求得抗拉強度，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。

關鍵字

超音波鑲嵌 ； 聲波焊頭 ； 有限元素分析 ； 模態分析 ； 自然頻率 ； 田口方法

並列摘要

This study applied ultrasonic welding technology to inserted work, and developed an ultrasonic-aided inserting machine. This machine uses the shock excitation of ultrasonic transducers to transfer this vibration energy to metal insert through the magnified displacement of sonic welding head. There is violent friction between the metal insert and the thermoplastic material, which would result in high temperature instantly. When the thermoplastic material reaches the thermal deformation temperature, local plastic is in a half-molten state, and applies pressure on the insert and into the thermoplastic material. The molten plastic flows into the texture section on the surface of metal insert and the bottom cut, so as to obtain the effect of ultrasonic inlay.
In addition, the key point of ultrasonic inserted work efficiency is the design of ultrasonic head, and the quality of the sonic welding head influences the processing effect. Therefore, this study used ANSYS finite element analysis software to analyze and design the inserted ultrasonic head. The theoretical welding head in the optimum size was designed and produced based on the tapered ultrasonic head provided by the manufacturer. The ANSYS was used for vibration modal analysis to obtain the natural frequency, and conduct analysis and comparison. Finally, the theoretical welding head was measured by using a frequency instrument. The results showed the measured frequency was 14.8 kHz and close to 15 kHz from ultrasonic generator, which conformed to the simulation analysis value. The efficiency of welding head could be improved.
This machine tested on used plastic materials PVC and ABS for inserted work. The tensile strength of the tested samples was obtained through tensile test, and the optimal process parameter and the relative contribution of processing factors were obtained by using the Taguchi Method

並列關鍵字

ultrasonic inserting ； ultrasonic head ； finite element analysis ； modalanalysis ； natural frequency ； Taguchi Method

參考文獻

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