臺灣博碩士論文加值系統

蜂巢結構之材料因為其擁有高強度、高剛性以及重量輕的優勢，被廣泛應用於航太工業、建築產業以及軌道車輛工業等等。由於蜂巢結構材料的二次加工性很差，一般五軸加工機上，若刀具進給量參數設定有誤差，很容易在蜂巢結構上發現屈曲、脫膠或斷裂。基於對蜂巢結構材料的二次加工缺陷，以及加工效率的問題，因此以帶鋸機進行加工可以達到快速與低成本的效益，然而以帶鋸機加工受限於其加工靈活度低，因此要達到不同切削角度的高效能鋸切，必須對其不同切削角度之摩擦特性進行了解。
本研究量測帶鋸機鋸切振動、馬達電流以及鋸切造成的正向力與摩擦力，來探討蜂巢結構材料鋸切傾斜角度的變化對於鋸切的影響。因兩導輪座最接近鋸切點之固定件，利用加速規黏貼於兩側導輪座之軸向量測鋸切振動，了解鋸切時發生之振動行為。馬達為整個帶鋸機主要的動力來源，當鋸切阻力大時需要更大的電流來驅使馬達帶動鋸帶持續鋸切，建立馬達電流監控系統監測馬達電流變化。在特殊設計之夾具中埋入荷重元，量測鋸切時產生的負荷，與鋸切過程之正向力，換算後得到鋸切摩擦係數，是切削過程很重要的參數指標。利用調整鋸帶速度，來研究切削率、鋸帶速度以及蜂巢結構材料傾斜角度對振動、電流以及鋸切摩擦係數之相關性。
經由實驗結果顯示，當鋸帶轉速增加其低頻振動訊號較鋸帶轉速低時有減少趨勢，並且透過馬達電流分析當鋸帶轉速高時，馬達在鋸切過程中額外提供較少的扭矩，以確保鋸帶轉速在設定值。不同轉速在各個鋸切角度下的可觀察到，當鋸帶轉速在800 rpm時0度與5度鋸切角度之扭矩值是最大的，其次分別是10度與15度鋸切角，扭矩值之最大差異來到1.12 N-m，而在1000 rpm到1600 rpm之各區間皆是相同的趨勢，其中以鋸帶轉速1600 rpm時之扭矩誤差只有0.31 N-m。從不同鋸切角度看鋸切時鋸帶轉速變化中，鋸帶轉速800 rpm產生之馬達扭矩也是最大的，與1600 rpm相比之下，從0度、5度、10度以及15度之扭矩差異分別是，3.22 N-m、3.093 N-m、2.89 N-m以及2.31 N-m。透過鋸切的正向力以及鋸切材料的摩擦力之比值計算出鋸切摩擦係數發現在不同角度鋸切情況，依然是鋸帶轉速高時，摩擦係數相較於其他轉速的變化都是比較平穩的情況。透過不同的訊號量測分析找出鋸切最佳的鋸切條件。

This study investigates the influence of different sawing angle and different band saw cutting speed by measuring the sawing vibration, motor current and friction caused by sawing. The band saw carrier stand are the closest fixing parts of the sawing point, the sawing vibration was measured by the axis vector of the two adjustable band saw carrier stands, so that we can understand the main vibration behavior occurring during the sawing process. Motor is the heart of the band saw machine, more current is needed to drive when the sawing resistance is large, in case to ensure the smooth cutting process, motor current monitoring system is established to measure the motor current. The load cell is buried in the feeding plate to measure the sawing load, and also measure the normal force of the sawing process, used to calculate the coefficient of friction that caused by the sawing experiment in different parameters.
Results shows that the low frequency has a decreasing trend while the band saw speed increases, and when the band saw speed is high, the less motor torque is needed to saw the material. Under different band saw speed compared with each sawing angle it is shown that the motor torque value is the largest when the band saw speed at 800 rpm and the sawing angle respectively 0 degree, 5 degrees, 10 degrees, 15 degrees, the biggest motor torque value difference is 1.12 N-m, when the band saw speed is 1600 rpm, the biggest motor torque value difference is only 0.31 N-m. From 0 degree, 5 degrees, 10 degrees, 15 degrees of the sawing angle compared with band saw speed at 800 rpm and 1600 rpm, the differences are 3.22 Nm, 3.093 Nm, 2.89 Nm, and 2.31 Nm, respectively. It also has the largest motor torque value when the band saw speed is 800 rpm. Through the ratio of sawing force and the sawing friction, we can calculate the coefficient of friction in different sawing angle compared with different band saw speed, it is shown that the coefficient of friction has a smoother situation while the band saw speed is high. This study helps us to reveal sawing characteristics of the paper honeycomb plate and find out better sawing conditions through different signal measurements.

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 前言.....1
1.2 研究動機與目的.....1
1.3 文獻回顧.....2
1.3.1 振動量測分析.....2
1.3.2 蜂巢結構材料.....3
1.4 本文架構.....3
第二章 基礎理論.....5
2.1 鋸床構造.....5
2.1.1 鋸弓系統.....6
2.1.2 物料平台夾持系統.....6
2.1.3 電控系統.....6
2.1.4 機台底座.....6
2.2 鋸帶.....7
2.2.1 鋸帶結構.....9
2.2.2 鋸帶規格.....9
2.2.3 鋸帶齒型.....10
2.2.4 鋸齒齒組排列形式.....11
2.2.5 齒鋸形式.....12
2.3 鋸帶速度與鋸床切削率.....12
2.4 數位訊號處理 (Digital Signal Processing).....12
2.4.1 取樣定理 (Sampling Theorem).....12
2.4.2 快速傅立葉轉換 (Fast Fourier Transform, FFT).....13
2.4.3 時頻分析 (Time-frequency analysis).....13
2.5 均方根法 (Root Mean Square, RMS).....14
2.6 移動平均法 (Moving Average method).....14
2.7 應變 (Strain).....14
2.7.1 應變規 (Strain Gauge).....15
2.8 振動 (Vibration).....16
2.8.1 加速規 (Accelerometer).....16
2.9 電流量測方法.....17
2.10 蜂巢結構材料 (Honeycomb structure).....17
第三章 研究方法與實驗規劃.....21
3.1 研究流程.....21
3.2 實驗設備.....21
3.2.1 小型高速鋸帶機.....21
3.2.2 實驗儀器.....25
3.3 實驗規劃.....29
3.3.1 量測位置與方法.....29
3.3.2 鋸切角度.....31
3.3.3 實驗參數.....32
3.3.4 實驗步驟.....33
第四章 結果與討論.....34
4.1 振動分析.....34
4.1.1 鋸切振動頻譜量測與分析.....34
4.1.2 鋸切振動時頻分析.....46
4.2 鋸帶機馬達電流分析.....52
4.2.1 馬達空轉電流分析.....52
4.2.2 鋸切馬達電流分析.....53
4.2.3 馬達扭矩分析.....59
4.3 鋸切振動均方根值與馬達電流比較.....60
4.4 鋸切摩擦係數.....65
4.4.1 鋸切正向力量測分析.....65
4.4.2 鋸切摩擦係數比較.....67
第五章 結論.....70
5.1 結論.....70
5.2 未來展望.....70
參考文獻.....72
Extended Abstract.....74

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