超音波輔助銅線抽拉之研究

The Study of Ultrasonic aided Copper Wire Drawing

游忠堡(Chung-Pao You)

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

本研究主要針對超音波振動輔助銅線抽拉加工方法進行分析探討，抽線加工是塑性加工的一種，其製程是將被拉伸材料的前端施加一定大小的拉力，使其通過斷面逐漸減小的模孔，使其斷面減縮和長度增加的塑性變形過程。抽拉後的金屬線會與模孔具有相同的尺寸和形狀。而超音波輔助抽拉加工其原理則是在ㄧ般抽線的過程中使抽線眼模或拉伸的線產生超音波振動，使在抽線過程中導入超音波振動能量的加工技術。此加工技術可以降低拉拔力、改善表面品質和提高加工效率，尤其是對解決難加工材料金屬線的抽拉更具功效。
本研究主要目的是探討超音波振動對拉線製程所產生的影響，為達到該目的，所以本研究開發出一套超音波拉線機構，以徑向之超音波震動方式，利用聲波焊頭以實驗方式探討超音波輔助抽線過程中，超音波震動頻率對抽拉力的變化，以及拉拔速度和振動強度對拉拔力的影響。本研究還利用有限元素法模擬驗證聲波焊頭的共振頻率是否達到所需條件，藉此提供設計者可先模擬加工，再使用田口方法，求得此機型之影響控制因子，以調整過後之因子做實驗驗證，再以田口法中之變異數分析找出各實驗因子的貢獻度，以作為機台主要系統開發之參考。
本研究還利用工具光學式顯微鏡和拉伸試驗機，在不同抽線參數條件下，研究超音波振動對黃銅線材質的微觀影響，還以電子顯微鏡進行金屬線之金相分析，並進行金屬線的抗拉力試驗。

關鍵字

超音波 ； 拉線機構 ； 有限元素法 ； 田口法 ； 變異數分析

並列摘要

This study analyzed and discussed the ultrasonic vibration-aided copper wire drawing processing method. The principle of ultrasonic-aided drawing processing is to make the wire drawing die or the drawn wire generates ultrasonic vibration in general wire drawing process. It is a processing technology incorporating ultrasonic vibration energy in the course of wire drawing. This processing technology can reduce the drawing force, improve the surface quality and increase the working efficiency. It is especially effective for the drawing of wire of difficult-to-machine material.
The main purpose of this study is to discuss the effect of ultrasonic vibration on wire drawing process. Therefore, it developed an ultrasonic wire drawing mechanism, and discussed the influence of ultrasonic shake frequency on drawing force change, as well as that of drawing speed and vibration intensity on drawing force in the ultrasonic-aided wire drawing process by testing sonic drawing head in radial ultrasonic vibration mode. This study also used the finite element method to simulate and validate whether the resonance frequency of sonic welding head meets the required condition. Designers can simulate the processing first, and then use the Taguchi Method to obtain the control factors of this machine. The adjusted factors are for experimental validation, and the analysis of variance of the Taguchi Method is applied to find out the relative contribution of experimental factors, in order to provide a reference for the development of the primary system of machine.
This study also used an optical microscope and a tensile testing machine to discuss the microcosmic influence of ultrasonic vibration on brass wire under different wire drawing parameter conditions. An electron microscope was used for metallurgical analysis of wire, and the tensile test of wire was carried out.

並列關鍵字

Ultrasonic ； wire drawing mechanism ； finite element method ； Taguchi Method ； ANOVA(analysis of variance)

參考文獻

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