精密射出成型工件之超音波剝離技術研發

Research and Development of Ultrasonic Removing Technologies for Precision Injection Molding Workpiece

劉俊廷(Jun-Ting Liu)

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.2011.00061

摘要

本論文為研究一台具有快速剝離功能，可進行半自動加工的超音波振動剝離加工機。此加工機為利用超音波能量傳遞使之產生振動的加工方法所研發而成。此振動剝離型加工機，主要利用超音波振動子激振，透過聲波焊頭的放大位移，在焊頭下降接觸到工件後，在工件上建立起壓力，使結合面緊密接觸，達到觸發壓力時，把此振動能量傳到塑膠工件上。當焊頭與工件表面緊密接觸後會有振動摩擦產生而達到溫度上升的情況，得到超音波剝離效果。本研究設計製作出該振動剝離型加工機，並在剝離精密射出成型後之材料上有著顯著成效。此外，在這研究中，藉由實驗得到剝離效果及工件彈落距離之情況進而設計出集料方法，再使用田口方法，找出最佳製程參數及加工因子之貢獻率，再經由確認實驗驗證，最後求得此機種的較佳控制因子，提升加工品質。
此外，超音波剝離加工效率，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，進行剝離之聲波焊頭分析與設計。以廠商所提供之階梯型聲波焊頭做為尺寸基礎，設計製造出較佳尺寸之理論焊頭，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，測得之頻率為19.8 kHz且接近於超音波產生器所產生之20kHz，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。
本實驗測試剝離材料為PC，聲波焊頭選用階梯型聲波焊頭，頻率選定20 kHz，剝離機的輸出功率設定為2200瓦特，剝離後觀察其工件彈落距離及其確實剝離效果，可得到發振時間與熔接壓力為此加工影響之最大因素。

關鍵字

聲波焊頭 ； ANSYS ； 超音波剝離 ； 精密射出成型 ； 模態分析

並列摘要

This study developed a semi-automatic ultrasonic vibration removing processor with fast removing capability. The processor was developed based on the processing method of using ultrasonic energy transfer to generate vibration. The vibration removing process uses the vibration produced by ultrasonic generators to build pressure on the workpiece when the horns is lowered to contact it through the amplification displacement of the horns to closely contact the joint surface. When the pressure reaches the trigger level, the energy will be transferred to the plastic workpiece. The close contact of the horns and the workpiece surface will cause vibration friction to raise the temperature, and thus the ultrasonic removal is achieved consequently. The proposed vibration removing processor designed in this study has significant effects on precision injection molding materials. In addition, this study designed the material collection method according to the removing effects and workpiece injection distances of the test, and used the Taguchi method to determine the optimal processing parameters and processing factor contribution rate. Verified by the confirmation test, the final control factors of better results were obtained to improve the processing quality.
The ultrasonic removing processing efficiency mainly depends on the design of the horns. The strengths and weakness of the horns will affect the processing effects. Therefore, this study used the ANSYS finite element analysis software for the design and analysis of the horns. With the ladder-type hornss provided by manufacturers as the dimension basis, this study designed and implemented theoretical hornss of better size. This study then analyzed the vibration model ANSYS method for vibration model analysis to get the natural frequencies of the hornss for comparative analysis. Finally, the theoretical hornss were measured by using the frequency-measuring instrument. The measured frequency at 19.8 kHz was close to the frequency of the ultrasonic generator at 20kHz, and was consistent with the simulation analysis value. It can considerably reduce the trial and error testing time of dimension modifications in the welding process as well as enhance the horns performance.
In this study, the removal testing material was PC, the horns was the ladder-type horns, the frequency was set as 20 kHz, the output power of the removing machine was set as 2200 Watt. By observing the workpiece injection distance and the actual removing effects, it can be found that the vibration time and welding stress are the processing factors of maximum impact.

並列關鍵字

Horns ； ANSYS ； Ultrasonic Removing ； Precision Injection Molding ； Model Analysis

參考文獻

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