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研究生： 洪郁婷
Hung, Yu-Ting
論文名稱： 電磁懸浮熔煉技術中線圈設計對金屬球懸浮力的影響：數值模擬系統建立及其實驗驗證
Development of a Numerical System and its Experimental Validation on the Effect of Coil Design on Levitation Force of Metal Ball in Electromagnetic Levitation Smelting Technique
指導教授： 郭瑞昭
Kuo, Jui-Chao
學位類別： 碩士
Master
系所名稱： 工學院 - 材料科學及工程學系
Department of Materials Science and Engineering
論文出版年： 2017
畢業學年度： 105
語文別： 中文
論文頁數： 142
中文關鍵詞： 電磁懸浮 、懸浮熔煉 、感應加熱 、數值模擬 、線圈設計
外文關鍵詞： levitation melting, magnetic levitation, induction heating, numerical simulation, coil design
相關次數： 點閱：81  下載：18 
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    • 電磁懸浮熔煉 (Electromagnetic Levitation, EML) 為一種將金屬材料於懸浮狀態下加熱的熔煉技術，該製程結合電磁懸浮、電磁攪拌和感應加熱等技術，在加熱、熔化和凝固過程中其熔煉材料皆不需與容器接觸，可避免容器帶來的汙染，熔煉出高純度的材料。
    影響EML製程的主要因素為加熱頻率和線圈設計，頻率影響加熱速率與均勻性，線圈設計影響懸浮加熱之位置，但加熱頻率受限於機台，線圈設計因此為影響EML製程的指標。若以傳統的試誤 (Trial and error) 方式進行參數改良，會耗費許多成本與人力，故本研究採用電腦數值模擬技術進行EML製程之模擬。目標在於建立其數值模擬系統，探討線圈設計對懸浮力的影響，內容包含電磁場、懸浮力、平衡高度和溫度場分布。
    模擬結果利用熔煉過程的實驗結果進行驗證，可以分成三個部分：第一部分為鋼球和鈦球於線圈A和B下的懸浮高度，模擬與實驗有一致的高度位置。第二部份為大小顆鋼球於線圈A下的懸浮力，模擬與實驗具有相同的趨勢，當電流值增加，浮力值也有增加的趨勢，而且大顆鋼球的浮力值約為小顆鋼球的兩倍左右，驗證了電磁場的可信度。第三部分為鈦球於線圈B下的溫度，同樣是加熱190秒，模擬溫度為1402 oC，實驗為1421 oC，誤差百分比為1.3%，驗證了模擬溫度場系統的可信度。
    另外，模擬建立線圈C和D隨高度變化的懸浮力，並預測其懸浮的高度，同時比較線圈A、B、C和D的設計，得到線圈的匝數與上下排間距是影響金屬球平衡高度的主要因素，而線圈纏繞直徑影響則較小。

    Electromagnetic levitation (EML) technique uses alternative currents generate electromagnetic field and Lorentz force which induces eddy currents and thus, it leads to lifting and to heating the metal sample at the same time. In this study, we considered magnetic field and heat transfer in solid by using the commercial numerical simulation software, COMSOL Multiphysics®, in order to develop a numerical simulation model to investigate the effect of coil design in EML process. Simulation results agree with the experimental results of electromagnetic distribution, levitation force, the height in equilibrium and the thermal distribution of metal ball. Considering the coil design composed of the upper part and the lower part, it can conclude as follows: increasing the turns of the upper part and decreasing the gap of coil between the upper and the lower part results in decreasing the equilibrium height. In addition the winding of the upper part is not the main influence in equilibrium.

    摘要 I Extended Abstract III 誌謝 XI 總目錄 XII 表目錄 XVI 圖目錄 XVII 符號表 XXII 第一章 前言 1 第二章 文獻回顧 3 2.1 電磁懸浮熔煉之發展 3 2.2 電磁懸浮熔煉之應用 8 2.2.1 金屬固化過程 8 2.2.2 量測熱物性質 9 2.2.3 製造奈米材料及金屬氣體分析 10 2.3 電磁懸浮熔煉之數值模擬 13 2.3.1 表面及液滴震盪 13 2.3.2 電磁場、溫度場與製程參數優化 15 2.4 線圈結構設計對樣品材料的影響 20 2.5 研究內容與目的 21 第三章 基礎理論與數值模擬 22 3.1 電磁懸浮模擬之基礎理論 22 3.1.1 電磁感應控制方程式 23 3.1.2 懸浮力計算 27 3.1.3 集膚效應與方程式 27 3.1.4 電熱轉換控制方程式 28 3.2 熱傳模擬之基礎理論 28 3.2.1 熱傳導方程式 29 3.3 數值模擬方法 30 3.3.1 模擬假設 32 3.3.2 模擬流程 33 3.3.3 模型建立 35 3.3.4 邊界條件與初始條件 39 3.3.5 材料熱物性質 40 第四章 實驗方法與步驟 41 4.1 實驗方法 41 4.2 實驗流程 42 4.3 實驗儀器 44 4.4 實驗材料 47 第五章 數值模擬與實驗結果 48 5.1 電磁場模擬與驗證 50 5.1.1 懸浮力 : 線圈A、鋼球 50 5.1.2 平衡高度 57 5.1.2.1 線圈A、鋼球 57 5.1.2.2 線圈B、鈦球 69 5.2 溫度場模擬與驗證 : 線圈B、鈦球 76 5.3 其他線圈電磁場模擬結果 82 5.3.1 線圈B、鋼球 82 5.3.2 線圈C、鋼球 89 5.3.3 線圈D、鋼球 95 第六章 討論 100 6.1 線圈設計對懸浮力的影響 100 6.1.1 上下排間距 : 線圈A vs. D 100 6.1.2 纏繞直徑 : 線圈B vs. C 103 6.1.3 線圈匝數 : 線圈C vs. D 106 6.1.4 金屬球材料 : 鋼 vs. 鈦 107 6.2 金屬球直徑對懸浮力的影響 108 第七章 結論 109 參考文獻 111

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