臺灣博碩士論文加值系統

在機械金屬加工中，超音波焊接的成功與否很大程度上取決於焊頭或超聲波發生
器的設計。焊頭必須以適當的水平進行振動，並有效地將振動能量傳遞到金屬接合
點，同時確保振動能量在傳遞過程中不明顯損失，以獲得高質量的焊縫。因此，準確
的超聲波焊頭設計對於實現有效的超音波金屬焊接至關重要。
本研究的重點是使用 ANSYS 有限元素分析軟體進行聲波焊頭的模態分析，透過田
口法的望目特性，找到符合設計目標值的聲波焊頭尺寸。接著使用頻率量測儀對製作
出的最佳化聲波焊頭進行頻率量測，並進行模擬比對，比對結果顯示實際測量值與模
擬值相似，對超音波加工上節省大部分測試與修正時間。
實驗以黃銅片和銅線作為實驗材料，透過施加不同的壓力、銅線粗細和熔接時間
作為因子進行試驗。配合光學顯微鏡和拉伸試驗機來評估不同熔接參數條件對超音波
熔接的影響，以田口法，找出最佳的製程參數和加工因子，並評估每個因子對產品品
質的貢獻率，藉此改善超音波熔接的加工過程，提高最終產品的品質。

In mechanical metal processing, the success of ultrasonic welding largely depends on the
design of the weld head or ultrasonic generator. The weld head must vibrate at an appropriate
level and effectively transfer vibrational energy to the metal joint while minimizing energy
losses during the transmission process to achieve high-quality welds. Therefore, accurate
design of the ultrasonic weld head is crucial for achieving effective ultrasonic metal welding.
The focus of this study is to perform modal analysis of the ultrasonic weld head using
ANSYS finite element analysis software. By utilizing the desired characteristics of the
Taguchi method, the optimal dimensions of the ultrasonic weld head that meet the design
objectives are determined. Subsequently, a frequency measuring instrument is used to
measure the frequency of the optimized weld head that has been fabricated, and the measured
values are compared with the simulation results. The comparison demonstrates similarity
between the measured and simulated values, thus saving significant testing and refinement
time in ultrasonic processing.
The experiment involves using brass sheets and copper wires as the test materials.
Different factors such as applied pressure, wire diameter, and welding time are varied in the
experiment. Optical microscopy and a tensile testing machine are employed to evaluate the
impact of different welding parameter conditions on ultrasonic welding. Using the Taguchi
method, the optimal process parameters and processing factors are determined, and the
iii
contribution of each factor to the product quality is assessed. This approach aims to improve
the ultrasonic welding process and enhance the quality of the final product.

摘要.....................................................................................................................................i
Abstract...............................................................................................................................ii
誌謝...................................................................................................................................iv
目錄....................................................................................................................................v
表目錄..............................................................................................................................vii
圖目錄.............................................................................................................................viii
符號說明...........................................................................................................................ix
第一章 緒論......................................................................................................................1
1.1 研究背景與動機..................................................................................................1
1.2 研究目的..............................................................................................................1
1.3 論文架構..............................................................................................................1
第二章 文獻回顧..............................................................................................................2
2.1 超音波焊接相關研究..........................................................................................2
2.2 理論基礎..............................................................................................................3
2.2.1 超音波基本原理及特性...........................................................................3
2.2.2 超音波金屬熔接原理...............................................................................6
2.2.3 超音波熔接方法.......................................................................................7
2.3 有限元素分析......................................................................................................8
2.3.1 有限元素法種類.......................................................................................9
2.3.2 有限元素分析重要名詞......................................................................... 11
2.4 田口方法原理介紹............................................................................................12
2.4.1 穩健分析.................................................................................................12
2.4.2 田口式品質工程之概述.........................................................................13
2.4.3 實驗設計步驟.........................................................................................14
2.4.4 田口法之實驗名詞解釋[15] ..................................................................15
2.4.5 直交表.....................................................................................................16
2.4.6 訊號雜訊比（S/N 比）..........................................................................18
2.4.7 變異數分析.............................................................................................19
第三章 聲波焊頭尺寸設計與分析................................................................................22
3.1 聲波焊頭尺寸設計............................................................................................22
3.1.1 材料性質.................................................................................................22
3.2 焊頭尺寸設定....................................................................................................23
3.2.1 直交表選用.............................................................................................24
3.2.2 數據分析.................................................................................................25
3.2.3 靈敏度調整分析.....................................................................................28
3.2.4 變異數分析.............................................................................................30
vi
3.2.5 確認實驗.................................................................................................31
3.3 實際聲波焊頭頻率量測....................................................................................32
第四章 超音波熔接實驗流程........................................................................................33
4.1 實驗設備介紹....................................................................................................33
4.1.1 焊接機.....................................................................................................33
4.1.2 音波產生器.............................................................................................34
4.1.3 配重組.....................................................................................................34
4.1.4 拉力試驗機.............................................................................................35
4.1.5 熱鑲埋.....................................................................................................35
4.1.6 光學顯微鏡.............................................................................................36
4.2 實驗流程............................................................................................................36
4.2.1 試片熔接.................................................................................................36
4.2.2 超音波熔接試片拉力測試.....................................................................38
4.2.3 超音波熔接試片表面熔接程度探討.....................................................39
4.3 應用田口法於加工實驗....................................................................................40
4.3.1 品質特性的選定.....................................................................................40
4.3.2 控制因子及其水準值.............................................................................40
4.3.3 直交表的選用.........................................................................................41
4.3.4 實驗數據分析.........................................................................................42
4.3.5 平均數分析(信號雜訊比 S/N 比) ..........................................................43
4.3.6 ANOVA 分析 ..........................................................................................45
第五章 結論與未來展望................................................................................................46
5.1 結論....................................................................................................................46
5.2 未來展望............................................................................................................46
參考文獻..........................................................................................................................47
Extended Abstract.............................................................................................................48
1. Introduction ..........................................................................................................49
2. Experiment ...........................................................................................................50
3.Results and Discussion ..........................................................................................50
4. Conclusion............................................................................................................51

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