在科技無時無刻進步的現在，產品尺寸精度及公差要求越來越精準，加工技術必須有新的突破，故對於材料的特性與適當的加工方式等都必須列入考量。工欲善其事必先利其器，凡是加工生產上都必須有適當的工具才能事半功倍。本文以切削加工為例，切削刀具的設計需針對材料性質及需求目標做考量，以達到目的之外同時也可以減少刀具在加工時所產生的磨耗現象。
鋁合金材質與鋼鐵相比，雖然剛性低但是它比鋼鐵還輕，具有優良的材料強度，成型性及抗腐蝕性等，因此鋁合金廣泛運用在航太零件、汽車輪圈、腳踏車車架、3C產品等。故本實驗以鋁合金進行切削實驗，加工目標主要選擇刃口磨耗量及加工後表面粗糙度，並選擇刀具主要切削之四個角度做為控制因子，利用L9田口直交表排列不同的刀具幾何做初步的分析，得到最佳切削刀具之幾何角度，再根據實驗結果排列L18田口直交表作最後的分析驗證，得到最少量的刀具磨耗及最好的加工後工件的表面粗糙度，由第一階段前測試實驗L9田口直交表實驗中發現，軸向切削角度不宜過大，於切削時造成20um以上之刃口崩損，加工後表面粗糙度範圍數值為0.6um，再經過第二階段L18田口直交表針對選用因子及角度範圍改善後得到最佳軸向刃口磨耗為6.064um，加工後工件的表面粗糙度下降至0.55um，獲得明顯改善。

With the progress of science and technology, product size and tolerance requirements are getting finer. There must be new breakthroughs in the requirements for dimensional accuracy and processing technology. Need to consider material properties, correct handling methods, etc. Good craftsmanship depends on the use of the right tools. All processing and production must have appropriate tools to do more with less. This paper uses cutting machining as an example to design the material properties of the cutting tool and the objectives to be considered. In order to achieve this goal, it is also possible to reduce the wear of the tool during machining.
Compared with steel, aluminum alloy has a lower rigidity, but it is lighter than steel. It has excellent material strength, formability, and corrosion resistance. Therefore, aluminum alloys are widely using in aerospace parts, automobile wheels, bicycle racks, 3C electrical products, etc. Therefore, this experiment using for cutting experiments of aerospace aluminum alloy and 3C products. For the processing object, the surface roughness of the cutting edge after grinding is mainly select, and the four factors of the main cutting tool are select. The L9 Taguchi orthogonal array is used for preliminary analysis of tools with different tool geometries and for cutting. Then according to the experimental results of the L18 Taguchi orthogonal array, the tool geometry is sorted for final analysis and verification. The smallest amount of tool wear and the best surface finish after machining.
From the first stage experiment L9 Taguchi orthogonal array test, the axial cutting angle not too large, the cutting edge of 20um or more during cutting, the surface roughness range is 0.6um, and second stage The L18 Taguchi Straight array has an optimum axial edge wear of 6.064um for the selection factor and angle range improvement. After processing, the surface roughness of the workpiece was reducing to 0.55 um, which was significantly improved.

摘要.................i
Abstract.................ii
誌謝.................iv
目錄.................v
表目錄.................vii
圖目錄.................viii
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.................1
1.4研究流程.................2
1.5論文架構.................2
第二章　基礎理論.................4
2.1刀具幾何角度.................4
2.1.1端銑刀之刃數.................4
2.1.2刀具刃口與螺旋方向.................5
2.1.3刀具幾何形狀.................5
2.1.4鋁合金之性質分類.................10
2.2切削理論.................10
2.2.1切削模型.................10
2.2.2切削型式[10].................11
2.2.3切削加工參數[11].................12
2.2.4刀具磨耗[10].................13
2.3田口方法[12].................14
2.3.1品質損失函數.................15
2.3.2訊號雜訊比.................15
2.3.3田口直交表.................16
2.3.4變異數分析.................17
2.3.5加法模式與信賴區間.................19
2.3.6灰關聯分析.................19
第三章　實驗軟體與設備.................22
3.1 WALTER-Tool Studio刀具設計軟體.................22
3.2 Bridge 8匠澤工具機.................23
3.3 KEE JAAN TP-300AE砂輪量測儀.................23
3.4 WALTER BASIC刀具研磨機.................24
3.5 KEEJAAN KJ-202影像測量系統.................25
3.6 Zoller genius3s刀具量測儀.................25
3.7 Olympus STM 6高精度工具顯微鏡.................26
3.8 Surfcorder SE-4000表面粗糙度測量儀.................27
第四章　測試與實驗設計規劃.................28
4.1第一階段前測試實驗.................28
4.2第一階段前測試實驗結果.................29
4.2.1第一階段前測試實驗之刀具磨耗.................30
4.2.2第一階段前測試實驗之加工後表面粗糙度.................31
4.2.3第一階段前測試實驗結論.................31
4.3第二階段主實驗設計.................34
4.3.1刀具配置與研磨.................34
第五章　實驗結果.................37
5.1軸向刃口磨耗.................37
5.2加工後表面粗糙度(Ra).................38
5.3 S/N比計算.................39
5.4因子效應.................40
5.5變異數分析.................41
第六章　結論與未來展望.................43
6.1結論.................43
6.2未來展望.................43
參考文獻.................44
Extended Abstract.................46
Abstract.................46

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