超音波加工是非傳統加工之一，超音波變幅桿是超音波加工中的主要元素件，它是機器和工件間的介質。本研究採用SJ-26a超音波機 ，針對射出成型的塑膠鏡筒，設計一超音波變幅桿，以在一次衝程中將所有塑膠鏡筒分離。大多數機械加工透過使用刀具、熱線和雷射切割，將塑膠鏡筒分離。這些方法都會產生熱量並且消耗更多的加工時間。超音波加工將塑膠鏡筒分離，而不會產生熱量，並且消耗的時間也非常少。
本研究使用有限元素分析(FEA)設計在15KHz頻率下，產生低應力與徑向振動運動之超音波變幅桿。與SJ-26a比較，本研究設計的超音波變幅桿，具有較低的應力、定向變形量與總變形量，其最大主應力為0.11761 MPA。調整後的超音波變幅桿，其分離塑膠鏡筒的振動時間為0.29秒，在工件上的靜止時間為0.48秒，在這些調諧參數下，其能夠在一個週期內從工件上分離所有的塑膠鏡片。

Ultrasonic machining is one of oldest non-traditional machining process, ul-trasonic horn is main element in ultrasonic machine, because its acts as medium in between machine and workpiece. In this study, design ultrasonic horn , which can be able to break off all plastic-lens barrel from gates in a single stroke. SJ-26a ultrasonic machine is used for this study. Plastic-lens barrel are manufactured by injection moulding. Many machining operations are available to break off plastic-lens barrel from gates by means of cutting using blade, hot wire and laser, every method produce heat and also consume more machining time, but ultrasonic ma-chining break off plastic-lens barrel from gates without producing heat and also consumes very less time.
The main aim of this study is design ultrasonic horn at 15KHz until to produce longitudinal vibrational motion at 15KHz frequency and low stress concentration in FEA. By comparing results of optimum ultrasonic horn design with SJ-26a ul-trasonic machine horn. The Stresses, directional deformation, and total defor-mation of our optimum ultrasonic horn design are very low. The maximum prin-cipal stress of our design is 0.11761 MPA. After tuning ultrasonic horn in ultra-sonic machine, the vibration time is 0.29 seconds and the rest time of ultrasonic horn on workpiece is 0.48 second. The ultrasonic horn is able to break all plastic-lens from gates of workpiece within a single cycle at these tuning parameters.

Chinese abstract ...................................................... i
English abstract .................................................... ii
Acknowledgements ................................................... iv
Table of Content ..................................................... v
List of Tables ........................................................ vi
List of Figures ......................................................... vii
Chapter 1 Introduction ........................ 1
1.1 Motivation ........................................1
1.2 Background ...............................1
1.3 Objective ...........................................................2
1.4 Research method .....................3
1.4.1 Selection of Ultrasonic Horn Shape......................................................................... 3
1.4.2 Selection of Suitable Material to Ultrasonic Horn ................... 4
1.4.3 Design of Ultrasonic Horn ..................... 4
1.5 Thesis Organisation ...................................6
Chapter 2 Design Calculation and Horn Shape ................................. 7
2.1 Design Calculation ...............................................................................................7
2.2 Ultrasonic Machining Operation ........................................................................9
2.3 Ultrasonic Horn and Workpiece Base holder ................................................ 11
Chapter 3 Plastic-Lens Barrel .................................................................................... 13
3.1 Plastic-lens Barrel ............................................................................................. 13
3.2 Rectangular Plastic-lens Barrel ....................................................................... 14
3.3 Circular Plastic-lens Barrel ............................................................................. 16
Chapter 4 Design and Analysis of Ultrasonic Horn ................................................... 18
4.1 Methodology for ultrasonic horn design ....................................................... 18
4.2 One Dimensional Wave Equation Horn Design ........................................... 20
4.3 Ultrasonic Horn Design as Per Previous Studies ......................................... 23
4.4 Optimum Ultrasonic Horn design .................................................................. 26
4.5 SJ-26a Ultrasonic Machine Horn Design: ..................................................... 30
Chapter 5 RESULTS .................................................................................................. 33
5.1 Harmonic Analysis Results at 15Khz frequency .......................................... 33
5.2 Experimental Results ....................................................................................... 34
Chapter 6 Conclusion ................................................................................................. 41
References ................................................................................................................................ 42
Extended abstract ...................................................................................................................... 44

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