臺灣博碩士論文加值系統

超音波焊頭在超音波加工系統中具有振幅放大、減小諧振阻抗等功用，主要功用是於振動時能將位移或速度放大，並將超音波能量集中在較小的面積上，是超音波振動系統設計中的重要組成部分，超音波焊頭的常見設計方法主要有以下五種方法，解析法、等效電路法和等機械阻抗法、轉換矩陣法和有限元法。

超音波焊頭的各種參數可以通過複雜的計算或傳統的分析方法獲得。然而在一般的最佳化設計流程中，往往是針對單一性能目標，改變幾何參數來進行優化，然而上述的做法並不能找出各設計變數與性能目標的關聯性、設計的準則與優化的定律，也不能量化設計參數對於性能目標的影響。
因此一個良好的最佳化設計，必須能夠建立輸入參數與輸出參數的關聯性，讓設計者能依照多個不同的性能目標，在參數間取捨，得到最佳化設計的結果，而ANSYS DesignXplorer不僅提供了如上述最佳化設計的功能而且大大簡化了計算過程。

本論文係以ANSYS Workbench針對製造超音波加工機的公司所提供之市售超音波焊頭做模態分析，並進行超音波焊頭頻率測試來驗證模擬分析後所得到之動態特性參數，最後以ANSYS DesignXplorer來進行反應曲面最佳化，並將設計結果與市售焊頭進行比較。

Ultrasonic horn has the functions of amplifying amplitude and reducing resonant impedance in ultrasonic system. Its primary function is to amplify deformation or velocity during vibration and focus ultrasonic energy on the small area. It is a crucial component in design of ultrasonic vibration system.There are five common design methods for ultrasonic horns: analytical method, equivalent circuit method, equal mechanical impedance, transfer matrix method, finite element method.

In addition, the general optimization design process is to change the geometric parameters to improve a single performance. Therefore, in the general optimization design process, we couldn't find the relation of parameter and objective. However, a good optimization design must be able to establish the relationship between input parameters and output parameters, so that the designer can choose between parameters according to different performance objectives and obtain the results of the optimization design.

In this study, an ultrasonic horn provided by Maxwide Ultrasonic co., Ltd., was used as the contrast of optimized ultrasonic horn. The ANSYS finite element analysis software was used to simulate the distribution of the horn amplitudes and the natural frequency value. The results showed that the frequency for the simulation values and actual measurement values were similar, verifying the accuracy of the simulation values. The ANSYS DesignXplorer was used to perform Response Surface optimization which could shows the relation of parameter and objective. Therefore, this method can be used to substitute the traditional experience method or the trial-and-error method for design to reduce material costs and design cycles.

摘要......................................................................i
Abstract.................................................................ii
誌謝....................................................................iii
目錄....................................................................iv
表目錄..................................................................vi
圖目錄..................................................................vii
符號說明................................................................ix
第一章 緒論............................................................1
1.1 研究背景........................................................ 1
1.2 研究目的..........................................................1
1.3 參考文獻回顧....................................................2
1.4 論文架構.........................................................4
第二章 相關理論基礎.................................................. 5
2.1 超音波加工原理相關介紹............................................5
2.2 超音波塑膠加工原理.................................................6
2.3 水波原理及聲波反射之特性.................................................6
2.4 超音波焊頭概念簡介..................................................7
2.5 有限元素法簡介..................................................8
2.6 有限元素法種類..................................................9
2.7 有限元素分析重要名詞..................................................10
2.8 振動與模態基礎理論..................................................12
2.9 模態分析重要名詞..................................................12
第三章 模態分析與共振頻率量測..................................................13
3.1 實驗流程 ..............................................................13
3.2 模型設計 ...........................................................14
3.3 材料性質 ...........................................................15
3.4 網格劃分 ...........................................................15
3.5 收斂性分析.........................................................15
3.6 模態分析 ..........................................................16
3.7 音頻產生器.........................................................20
3.8 頻率顯示器.........................................................21
3.9 超音波焊頭.........................................................22
3.10 量測實驗方法.......................................................22
第四章 最佳化設計工具 DesignXplorer.......................................24
4.1 反應曲面法........................................................24
4.2 最佳化設計流程....................................................27
4.3 超音波焊頭尺寸參數化設計...........................................28
4.4 設計變數與性能目標................................................29
4.5 DOE實驗設計法....................................................30
4.6 設計變數與性能目標之反應曲面....................................34
4.7 篩選優化 ......................................................40
第五章 結果討論 ........................................................41
5.1 量測超音波焊頭共振頻率結果........................................41
5.2 擬合度分析......................................................42
5.3 靈敏度分析.......................................................45
5.4 篩選優化結果......................................................46
5.5 柏拉圖最適分析結果.................................................47
5.6 最佳化參數驗證結果.................................................48
第六章 結論與未來展望......................................................50
6.1 結論................................................................50
6.2 未來展望 ..........................................................51
參考文獻 ..................................................................52
Extended Abstract........................................................53
Abstract...............................................................53
1. Introduction....................................................53
2. Finite Element Analysis and Response Surface optimization......54
3. Discussions and Conclusion....................................55
Reference.............................................................55

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