臺灣博碩士論文加值系統

鎳鈦(NiTi)形狀記憶合金被廣泛運用於醫療及工業工程上之應用，且擁有形狀記憶效應、超彈性、高阻尼容量、非傳統的應力-應變行為等特性，導致一般機械加工變得非常困難，除此之外，切削鎳鈦記憶合金時毛邊的生成與黏著，會導致非常高的刀具磨耗、大的切削力與不良的工件品質。
本研究利用Design Expert分析軟體進行參數設計與分析，以主軸轉速、進給率及切削深度作為反應變數，而表面粗糙度、刀腹磨耗及切削力則為反應值，進行反應曲面法之中央合成設計3因子5水準實驗。分別使用無輔助、雙軸向超音波及冷風輔助等進行鎳鈦形狀記憶合金銑削實驗，各種實驗依反應設計20組參數依序完成實驗後，再將結果代回Design Expert分析軟體中分析，並以完成面粗糙度為目標函數且受制於刀具磨耗與切削力的拘束條件，藉由反應曲面法尋找最佳或較佳製程參數組合，並預測表面粗糙度、刀腹磨耗及切削力，此結果與進一步實驗驗證相符。實驗中發現，於特定參數組合可以觀察到火花現象，且於工件上也明顯發現毛邊的堆積。而本文利用實驗切削力計算應力值代入拉伸試驗的應力應變圖中進行對比，找出應力誘發相變化的臨界點。不論在何種參數組合下，冷風輔助皆可以有效抑制金相轉換，明顯改善工件品質。

Nickel-Titanium shape memory alloys (SMA) have been widely used for medical and industrial engineering applications. It possess several excellent properties such as shape memory effect, superelasticity, high damping capacities, unconventional stress-strain behavior, etc., which making the traditional machining of SMA is very difficult to be executed. In addition, the formation and adhesion of the burrs occurring in the cutting of NiTi SMA causes a high abrasion in cutting-tool, larger cutting force and poor machining quality.
In this study, the analysis software of Design Expert was used for process parameter planning and relevant response analyses. The central composite design of the response surface methodology was applied to achieve a three-factor and five-level experiment planning, in which the spindle speed, feed rate and depth of cut were used as the response variables while surface roughness, flank wear and cutting force were the response values. The side milling experiments with NiTi SMA were carried out without assistance, and by biaxial ultrasonically assisted and cold-air assisted cutting, respectively. Based on the response design, each 20 sets of process parameter combination experiments for different assisted systems was conducted, respectively. The response surface methodology was applied to determine the optimal or better combination of process parameters for NiTi SMA milling, in which the machined surface roughness, and cutting force and cutting-tool wear are used as object function and subjecting constraints, respectively, As a result, the surface roughness, flank wear and cutting force were predicted consequently, which are validated by a further experiment to ascertain the consistency. It was found that a spark phenomenon can be observed during the milling processes under a specific combination of process parameters, and the accumulation of burrs was also constituted on the workpiece outer-edge obviously. In this study, the stress is calculated from the division of cutting force by cutting area, which is further compared with the stress-strain curve obtained from the tensile test to ascertain the critical point of the stress-induced phase transformation. Regardless of the combination of the process parameters, cold-air assisted system prevails over the other assisted systems, and can effectively inhibit the metallographic transformation and improve the machining quality significantly.

摘要 ................................................................... i
Abstract .............................................................. ii
誌謝 ................................................................. iv
目錄 ................................ ................................ v
表目錄 ............................................................... vi
圖目錄 ............................................................... vii
第一章 前言 ........................................................... 1
1.1 研究背景 .......................................................... 1
1.2 研究動機與目的 .................................................... 4
1.3 文獻回顧 ...........................................................5
1.4 論文架構 ................................ ........................ 10
第二章 理論基礎 ....................................................... 11
2.1 鎳鈦形狀記憶合金特性及應用 ......................................... 11
2.2 輔助技術介紹 ...................................................... 14
2.3 反應曲面法 ........................................................ 16
第三章 實驗方法與規劃 .................................................. 20
3.1 工件材料與刀具特性 ................................................. 21
3.2 實驗儀器設備與規格 ................................................. 22
3.3 實驗方法與執行步驟 ................................................. 30
第四章 實結果與討論 .................................................... 33
4.1 無輔助銑削 ........................................................ 34
4.2 雙軸向超音波輔助銑削 ............................................... 47
4.3 冷風輔助銑削 ...................................................... 56
4.4 Deform銑削模擬分析銑削模擬分析 ..................................... 70
4.5 不同輔助銑削之比較 ................................................. 72
第五章 結論 ............................................................103
參考文獻 .............................................................. 104
附錄 A-1 ............................................................. 106
附錄 A-2 ............................................................. 107
附錄 A-3 ............................................................. 108
附錄 B-1 ............................................................. 109
附錄 B-2 ............................................................. 110
附錄 B-3 ..............................................................111
Extended Abstract .................................................... 112

[1]Y. Kaynak, H.E. Karaca, R.D. Noebe, I.S. Jawahir, 2013, Tool-wear analysis in cryogenic machining of NiTi shape memory alloys: A comparison of tool-wear performance with dry and MQL machining, Wear, Vol.306, pp.51-63.
[2]K. Weinert, V. Petzoldt, 2008, Machining NiTi micro-parts by micro-milling, Materials Science and Engineering A, Vol.481-482, pp.672-675.
[3]K. Weinert, V. Petzoldt, D. Kotter, 2004, Turning and drilling of NiTi shape memory al-loys, ClRP Annals, Vol.53, pp.65-68.
[4]R. Piquard, A. D’Acunto, P. Laheurte, D. Dudzinski, 2014, Micro-end milling of NiTi bi-omedical alloys, burr formation and phase transformation, Precision Engineering, Vol.38, pp.356-364.
[5]S.K. Wu, H.C. Lin, C.C. Chen, 1999, A study on the machinability of a Ti49.6Ni50.4 shape memory alloy, Materials Letters, Vol.40, pp.27-32.
[6]Ahmad Nabil Mohd Khalil, Azwan Iskandar Azmi, Muhamad Nasir Murad, Mohd Asyraf Mahboob Ali, 2018, The effect of cutting parameters on cutting force and tool wear in machining nickel titanium shape memory alloy ASTM F2063 under minimum quantity nanolubricant, Procedia CIRP, Vol.77, pp.227-230.
[7]K. Weinert, V. Petzoldt, 2004, Machining of NiTi based shape memory alloys, Materials Science and Engineering A, Vol.378, pp.180-184.
[8]Y. Kaynak, H.E. Karaca, R.D. Noebe, I.S. Jawahir, 2013, Analysis of tool-wear and cutting force components in dry, preheated, and cryogenic machining of NiTi shape memory alloys, Procedia CIRP, Vol.8, pp.498-503.
[9]H.C. Lin, K.M. Lin, Y.C. Chen, 2000, A study on the machining characteristics of TiNi shape memory alloys, Journal of Materials Processing Technology, Vol.105, pp327-332.
[10]Y. Kaynak, H.E. Karaca, I.S. Jawahir, 2014,Surface integrity characteristics of NiTi shape memory alloys resulting from dry and cryogenic machining, Procedia CIRP, Vol.13, pp.393-398.
[11]Yuebin Guo, Andreas Klink, Chenhao Fu, John Snyder,2013, Machinability and surface integrity of Nitinol shape memory alloy, CIRP Annals-Manufacturing Technology, Vol.62, pp.83-86.
[12]Y. Kaynak, S.W. Robertson, H.E. Karaca, I.S. Jawahir, 2015, Progressive tool-wear in machining of room-temperature austenitic NiTi alloys: The influence of cooling/lubricating, melting, and heat treatment conditions, Journal of Materials Processing Technology, Vol.215, pp.95-104.
[13]Y. Kaynak, S. Manchiraju, I.S. Jawahir, 2015, Modeling and simulation of machining-induced surface integrity characteristics of NiTi alloy, Procedia CIRP, Vol.31, pp.557-562.
[14]M.C. Kong, D. Axinte, W. Voiceb, 2011, Challenges in using waterjet machining of NiTi shape memory alloys: An analysis of controlled-depth milling, Journal of Materials Pro-cessing Technology, Vol.211, pp.959-971.
[15]W. Theisen, A. Schuermann, 2004, Electro discharge machining of nickel-titanium shape memory alloys, Materials Science and Engineering A, Vol.378, pp.200-204.
[16]Zainal A Zailania, Paul T Mativenga, 2016, Effects of chilled air on machinability of NiTi shape memory alloy, Procedia CIRP, Vol.45, pp.207-210.
[17]Dirk Biermann, Felix Kahleyss, Tobias Surmann, 2009, Micromilling of NiTi shape-memory alloys with ball nose cutters, Materials and Manufacturing Processes, Vol.24, pp.1266-1273.
[18]Han Huang, 2004, A study of high-speed milling characteristics of Nitinol, Materials and Manufacturing Processes, Vol.19, pp.159-175.
[19]Mehrshad Mehrpouya, Abed Moheb Shahedin, Sarmad Daood Salman Dawood, Ahmad Kamal Ariffin, 2016, The influence of machining parameters on turning process of NiTi shape memory alloys, Materials and Manufacturing Processes, Vol.32, pp.1497-1504.
[20]D. Biermann, F. Kahleyss, E. Krebs, and T. Upmeier, 2010, A study on micro-machining technology for the machining of NiTi: Five-axis micro-milling and micro deep-hole drilling, Journal of Materials Engineering and Performance, Vol.20, pp.745-751.