- 學位論文
超音波輔助切割機焊頭分析與研究
The Analysis of the Horn for Ultrasonic Cutting Machine
摘要
玻璃、陶瓷等硬脆材料在電子零組件及光學零組件中為必要之材料，但此種材料被歸類為不易切削材料，在加工製程中也容易產生瓶頸，例如材料易消耗、刀具壽命短，工件尺寸也因工作平台設限而無法加工。這些材料最常使用鑽石砂輪片進行切割，但由於鑽石砂輪片價格昂貴，因此如何延長其壽命及增加其切割速度為業者所專注之課題。本研究即針對此課題，進行將切割與超音波結合方面之研究，利用超音波快速震動來減少因刀片切割而破壞的加工表面，也避免材料在刀具上的黏滯，進而增加刀具之壽命。 本研究並對刀具焊頭進行設計及分析，利用有限元素法分析及製作最佳形狀焊頭(Horn)外，亦進行相關加工參數如焊頭形狀、焊頭材質、刀具尺寸、進給速度之加工參數研究，希冀將研究所得成果進行專利申請、論文發表外，還將技術資料提供配合廠商，使其能持續立足於超音波加工事業。 結果顯示，利用有限元素軟體分析配合田口方法所得到之自然頻率與實際測量相符，而影響切割實驗之表面粗糙度值最大之因子為焊頭轉速，其貢獻率佔整體之41.61%。
並列摘要
Hard and brittle materials, such as glass and ceramics, are necessary to produce electronic parts and components and optical parts and components. However, these materials are difficult to cut and are likely to cause bottlenecks in processing procedures. For example, materials may be rapidly depleted, cutting tool lifecycles may be decreased, and work piece sizes may be impossible to process because of work platform limitations. Hard materials are commonly cut using expensive diamond grinding wheel blades. Therefore, extending tool lifecycles and increasing the cutting speed is crucial to businesses. This study explores the integration of ultrasound technology into cutting techniques. The rapid vibration of ultrasound waves is used to reduce the processed surface damage caused by cutting with blades and to prevent material adhesion to the blade or cutting tool, thus extending the tool life. In this study, a horn for a cutting tool was designed and analyzed. Finite element analysis (FEA) was employed and an optimally-shaped horn was produced. Additionally, relevant processing parameters, such as the horn shape, horn material, cutting tool size, and feed speed, were examined. The results of this study are intended for patent application, publication, and provision to cooperating companies to ensure that a competitive edge is maintained in the ultrasonic processing industry. The results showed that the natural frequency obtained using the finite element software analysis and Taguchi methods matched the actual measurements. The most influencing factor of surface roughness values in the cutting experiment was the horn speed, which accounted for 41.61% of the overall effect.