超音波熔接製程是一種不可逆向的製程，每一個熔接產品的好壞都會在幾秒內決定結果，因此超音波焊頭扮演不可或缺的角色，不管是模型設計、發振模態模擬、自然頻率計算、CNC加工品質、振幅均勻度量測計算都會影響到焊頭的整體表現。
本研究探討超音波應用在熔接加工的焊頭，藉由理論公式與經驗公式設計原始的模型，並使用3D繪圖軟體結合有限元素分析進行探討，過程中對焊頭外型尺寸使用實驗設計法來設定變數，加入變數求解範圍來求得參數，將此參數套入模型進行模態分析。本研究發現模擬頻率誤差值、振幅均勻度結果皆不太理想，因此進行二次最佳化設計，再次套入所求得參數再次進行模態分析與自然頻率計算，驗證結果顯示模擬誤差值從60Hz下降到31Hz，振幅均勻度從17%下降至9%，符合頻率誤差值小於40Hz，振幅均勻度小於10%的驗證標準。由於有限元素分析結果與實際結果非常接近，所以此研究所建立的方法，可針對焊頭設計有效的提升開發與驗證速度。

Ultrasonic fusion bonding process is a non-reverse process, each of a melt quality product will take the decision result in seconds, so the ultrasonic horn is to play an indispensable role. Whether in the design model, modal analysis, natural frequency calculation, CNC machining quality, amplitude uniformity measurement and calculation will affect the overall performance of the welding head.
In this study, the ultrasonic application welding process of the ultrasonic horn is investigated. The theoretical formula of the original design of the empirical formula model and 3D graphics software in conjunction with finite element analysis are employed. During the calculation of the horn outer size, the experimental design methods is used to set the variables and to add the variable solution range for obtaining the parameters. It is found that the error of the simulated frequency and amplitude uniformity are not ideal. Therefore, the second optimization design is carried out and the determined parameter modal for the natural frequency is calculated again. The verification result displays that the simulation error is reduced from 60 Hz to 31 Hz and the amplitude uniformity is reduced from 17% to 9 %. The frequency error is less than 40 Hz and the amplitude uniformity is less than 10% of the validation criteria. Because the finite element analysis results and the actual results are very close, so the method established by this research can effectively increase the speed of development and verification for welding head design.

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