臺灣博碩士論文加值系統

近年來科技與工業的蓬勃發展，切削加工產業已趨向高速與高精度切削等領域快速發展，故對於刀具品質的要求也越來越嚴苛，尤其在刀具幾何尺寸與角度更是極致的講究，才能符合現今高精度切削加工。本論文主要是以五軸磨刀機為主體建構出研磨端銑刀補正系統以提升刀具生產過程中的良率與效率，首先，必須要分析端銑刀具各部位之研磨製程，包含徑向切削角、徑向離隙角、軸向切削角、軸向離隙角，實驗目標為減少現場人員在補正時的人為疏失以及提升整體的補正效率。
第二部分建構完整的數學模組與類神經系統，可輸入端銑刀具各部位尺寸設計與端銑刀檢測值，經一連串縝密運算可以輸出準確的砂輪研磨點，此為大幅提升刀具製程時的刀具尺寸精度與幾何角度的關鍵因素。由實驗結果顯示，在刀具直徑4、6、8mm的徑向切削角誤差均可以在0.5度內，本實驗所開發的端銑刀補正軟體可以在最少的時間與成本情況下，達到所需端銑刀的研磨精度，提升現場生產效率，並降低刀具生產成本及人為疏失，如此可將刀具研磨製程標準化。

With the development of technology and industry recently, high-speed cutting and high accuracy cutting are the target in cutting industry. Therefore, the quality acquirement for tools will be stricter, especially for the more accurate geometry size and tool angle, which is in accordance with high accuracy cutting nowadays. This thesis aims for building up end mill offset system for five-axes grinding machines to enhance the yield rate and efficiency in tool production procedure. First, we analyze grinding procedure for all parts on tool, including radical cutting angle, radical relief angle, axial cutting angle and axial relief angle. The experiment targets are to reduce man-made mistake while worker does offset process, and boost overall offset efficiency.
The second part is to construct mathematical models and neural network. Via inputting the size of all parts on end mill and detection values of end mill, then sequential calculation, which we get accurate grinding point(s) of grinding machine. This is the key factor that greatly enhances tool size precision and geometry angle in the process. The result of the experiment indicates that the radial rake angle with tools whose diameter of 4, 6, 8 mm has each tolerance of 0.5 degrees. Thus, by using the end mill offset system used in this experiment, users can achieve end mill grinding accuracy that they desire under the condition that the least time and cost, which boosts production efficiency and geometry angle accuracy, and reduces tool production cost and man-made mistake. Thus, tool grinding procedure can be standardized.

摘要......... i
Abstract......... ii
誌謝......... iii
目錄 ......... iv
表目錄 ......... viii
圖目錄 ......... x
符號說明 ......... xiii
第一章 緒論 ......... 1
1.1 研究背景......... 1
1.2 研究動機與目的 ......... 1
1.3 文獻探討 ......... 1
1.4 研究流程 ......... 2
1.5 論文架構 ......... 4
第二章 理論基礎 ......... 5
2.1 端銑刀 ......... 5
2.1.1 端銑刀刃口介紹 ......... 5
2.1.2 端銑刀刃口與旋向 ......... 6
2.1.3 刀具幾何形狀.......... 7
2.1.3.1 徑向切削角......... 8
2.1.3.2 螺旋角......... 9
2.1.3.3 軸向切削角......... 9
2.1.3.4 徑向離隙角......... 10
2.1.3.5 軸向離隙角......... 12
2.2 磨削理論 ......... 12
2.2.1 砂輪磨粒 ......... 13
2.2.2 砂輪粒度 ......... 14
2.2.3 砂輪硬度 ......... 14
2.2.4 砂輪結合劑與製法 .......... 15
2.2.4.1 陶瓷燒結法 ......... 15
2.2.4.2 樹脂黏結法 ......... 16
2.2.4.3 金屬燒結法 ......... 16
2.2.5 磨耗機構 ......... 17
2.3 類神經網路應用 ......... 19
2.3.1 類神經網路基本理論 ......... 19
2.3.2 誘導式網路......... 20
2.3.3 誘導式網路建構步驟......... 22
2.3.4 誘導式網路參數設定.......... 22
第三章 實驗設備 ......... 23
3.1 Tool Studio研磨軟體 ......... 23
3.2 鑽石/CBN砂輪成型修整機......... 24
3.3 HELICHECK BASIC光學影像量測機......... 25
3.4 HELITRONIC BASIC刀具研磨機......... 26
3.5 Zoller genius3s刀具量測儀 ......... 27
3.6 KEEJAAN-KJ1000A 刀具影像量測儀......... 28
3.7 HAIMER-TOOL DYNAMIC 動平衡機 ......... 29
3.8 Abductory-Induction Mechanism......... 30
3.9 Labview 軟體.......... 30
第四章 建構刀具研磨精度補正軟體 ......... 31
4.1 建構流程 ......... 31
4.2 建構刀具與砂輪的空間幾何關係 ......... 31
4.2.1 徑向切削角 ......... 33
4.2.2 軸向切削角 ......... 33
4.2.3 徑向平離隙角 ......... 34
4.2.4 軸向平離隙角......... 34
4.3 建構刀具研磨精度補正邏輯 ......... 34
4.3.1 開槽砂輪直徑與位置誤差 ......... 35
4.3.2 攻角砂輪直徑與位置誤差 ......... 37
4.3.3 徑向離隙砂輪直徑與位置誤差 ......... 38
4.3.4 軸向離隙砂輪直徑與位置誤差 ......... 39
4.4 建構刀具補正精度數學式 ......... 42
4.4.1 開槽砂輪直徑與位置誤差 .......... 43
4.4.2 攻角砂輪直徑與位置誤差 ......... 45
4.4.3 徑向離隙砂輪直徑與位置誤差 ......... 47
4.4.4 軸向離隙砂輪直徑與位置誤差 ......... 50
第五章 實驗結果與驗證......... 52
5.1 研磨精度補正公式模擬驗證 ......... 52
5.1.1 開槽直徑與位置驗證 ......... 52
5.1.2 攻角位置驗證 ......... 54
5.1.3 徑向離隙砂輪直徑與位置驗證 ......... 55
5.1.4 軸向離隙砂輪位置驗證 ......... 57
5.2 研磨精度補正公式實際上機驗證 ......... 59
5.2.1 開槽直徑與位置驗證 ......... 59
5.2.2 徑向離隙砂輪位置驗證 ......... 60
5.2.3 軸向離隙砂輪位置驗證 ......... 61
5.2.4 刀具幾何角度驗證 ......... 62
5.3 研磨端銑刀精度補正系統介面撰寫 ......... 63
第六章 結論與未來展望 ......... 65
6.1 結論 ......... 65
6.2 未來展望 ......... 65
參考文獻 ......... 66
Extended Abstract ......... 68

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