迴轉式超音波大多應用於硬脆材料的鑽孔加工,目前在銑削應用的相關研究尚少,且銑削屬於水平切削加工,與超音波提供之縱向能量相互垂直,使超音波加工最重要的鎚擊作用無法於銑削時發揮出來,只剩下工具迴轉與微振動所產生的磨削作用,因此在現有的架構下要提高超音波銑削加工的效率,最簡便與快速的方法就從工具著手。 本研究之目的乃利用有限元素法設計銑削工具,以理論基礎設計加工面的形狀,搭配有限元素法模擬超音波的振動反應,以壓電陶瓷推動超音波振動系統,讓整個系統做簡諧運動,從中獲得其頻率、振幅與應力分佈。將所設計的工具搭配先前所設立的迴轉式超音波加工機,以玻璃工件做銑削實驗,探討進給速率與加工深度之相互影響,並以工具磨耗與工件表面精度為觀測之目標,探討超音波銑削對整體加工的效益。
Rotary ultrasonic drilling has been mostly used in the application of hard and brittle materials machining. In the field of researching the application, there is still less for ultrasonic machining(USM) milling. Because the hand of cut is vertical to ultrasonic vibration, the hammering mechanism of ultrasonic machining is not affect in milling. The material removal mechanism by rotary and vibration is only for abrasion. Designing the milling tool is the simplest and fastest method to increase the machining effects. The purpose of this study is using the finite element method(FEM) for tool design of milling, using the theory to design the working surface of milling and simulate the ultrasonic vibration by FEM. Piezoelectric drives out the result of the ultrasonic vibration for harmonic simulation. Using this simulation, we obtain the frequency, amplitude and stress that we needed. Using the design tool and rotary ultrasonic machine is for the experiment of glass milling. The result is from feed velocity and depth of machining. To observe the tool wear and surface roughness, the finial result of machining is to find out the efficacy of ultrasonic milling.