臺灣博碩士論文加值系統

隨著工業技術進步迅速，加工效率的提升已逐漸成為主流趨勢，然而機台組裝品質、材料性質以及刀具幾何都會引響加工的穩定性，以往只能依靠經驗進行加工，在現今已無法處理目前多變且複雜的加工條件，所以目前的加工廠透過切削力模型的預測與顫振預測的技術進行數值計算避開不穩定的轉速區間，藉此獲得穩定的切削參數，使工件得到較佳的表面粗糙度。有鑑於此本研究主要在刀具不同磨耗的狀態進行實驗，實驗分別為銑削之切削力預測系統、刀具顫振預測系統與動態切削監控系統，首先利用NACHI的高速鋼銑刀與鋁合金7075-T6進行銑削切削力實驗，研究出在刀具磨耗不同的狀態下切削力的變化，於X方向的切削力增加25%~ 32%，於Y方向的切削力增加3%~ 6%，最後計算切削力變化與進行線性回歸分析，鑑別出每種磨耗下之刀具對於鋁合金7075-T6之切削力係數。於刀具顫振預測系統分為刀具動剛性實驗與銑削穩定圖建置，刀具動剛性實驗以加敲擊錘與速度規進行敲擊實驗，將敲擊實驗取得之頻譜響應資料進行分析，計算出X與Y軸向的模態參數，最後將模態參數與切削力係數代入顫振穩定曲線演法，建立出主軸轉速與切削深度之間的關係，於顫振穩定圖之預測準確率達80%。於動態切削監控系統，本研究使用加速規與麥克風進行刀具顫振的量測，首先透過進行LabVIEW模組開發，將實驗獲得的音頻訊號進行分析，須從背景噪音與與其他干擾的音訊，篩選出顫振發生時的噪音，最後透過顫振的音訊與主軸震動即時的判斷是否處於顫振狀態，在電腦端分析刀具顫振發生時音頻的變化與加速規於主軸振動之訊號，由於顫振的發生可能以一個或多個頻率所引起的，所以透過此方式了解到顫振發生時加速規之頻率與刀具模態的主要頻率的位置關係，得知目前主要的顫振頻率點的振動值與顫振頻率，使加工時能即時得知機台是否處於不正當的加工狀態，初步驗證之成功率達95%。

With the rapid advancement of industrial technology, the improvement of processing efficiency has gradually becoming the mainstream trend. However, the assembly quality, material properties and tool geometry of the machine will lead to the stability of processing. In the past, it was only possible to rely on experience for processing, and this processing was hard to handle the current changing and complex processing conditions now, so the processing through the prediction of the cutting force model and the chatter prediction technology can obtain stable cutting parameters to avoid the unstable speed range for better surface roughness of the workpiece. In view of the fact, this study was mainly carried out in different wear states of cutting tools, the experiments such as the following: cutting force prediction system, chatter stability system and dynamic cutting monitoring system. Firstly, prediction of cutting force used NACHI high speed steel and Alloy 7075-T6, and researched cutting force and cutting coefficients under the different tool wear conditions, the cutting force is estimated by dynamic cutting, and the cutting force coefficients is calculated by linear regression during tool wear. The cutting forces of X direction grew 25% to 32%, and the cutting forces of Y direction grew 3% to 6%. Second, the chatter stability prediction system was divided into dynamic rigidity experiment and milling stability curve, the prediction of chatter stability applied analysis of frequency response data by dynamic rigidity experiments and cutting force coefficients. The preliminary determination of the corresponding cutting force coefficients was helpful for the prediction of the chatter stability, and this stability model constructed relationship between the spindle speed and cutting depth by regenerative chatter theory and frequency response function, the experimental results shew that the prediction accuracy was about 80%. Lastly, the dynamic cutting system for monitoring tool chatter used G-sensor and microphone to measure the resonant frequency of cutting, then it used the vibration value and frequency to know cutting chatter. The dynamic cutting monitoring system can know whether the machine was unstable machining state during processing, the success rate of verification was about 95%.

摘要.....i
Abstract.....ii
誌謝.....iii
目錄.....iv
表目錄.....vi
圖目錄.....vii
符號說明.....x
第 一 章 緒論.....1
1.1 研究背景與動機.....1
1.2 研究目的.....2
1.3 論文架構.....2
第 二 章 文獻回顧.....3
2.1 切削力係數相關研究.....3
2.2 刀具顫振穩定模態相關研究.....8
第 三 章 研究架構與方法.....14
3.1 研究架構與流程.....14
3.2 硬體及系統架構.....15
3.2.1 實驗機台介紹.....15
3.2.2 切削力實驗之硬體設備.....15
3.2.3 刀具動剛性實驗硬體設備.....16
3.2.4 實驗刀具與材料規格.....17
3.2.5 刀具磨耗量測設備.....18
3.3 銑削之切削力模型分析.....18
3.3.1 局部切削力解析.....18
3.3.2 直齒切削力模型解析.....20
3.3.3 端銑刀切削力模型.....21
3.3.4 平均切削力模型.....22
3.4 切削力係數鑑別.....24
3.4.1 動態切削力量測實驗.....24
3.4.2 平均切削力模型鑑別切削力係數.....25
3.5 刀具磨耗之顫振穩定預測.....26
3.5.1 刀具磨耗之影響.....26
3.5.2 刀具動剛性實驗.....26
3.5.3 顫振穩定曲線計算.....28
3.6 動態切削振動監控.....31
3.6.1 刀具之顫振監控系統.....31
3.6.2 麥克風音頻量測.....32
3.6.3 麥克風頻譜分析.....33
第 四 章 實驗結果.....35
4.1切削力係數鑑別.....35
4.1.2 切削力擷取實驗.....35
4.1.3 平均切削力與線性回歸分析.....37
4.2 刀具磨耗之穩定模態系統建置.....39
4.2.1 刀具動剛性實驗.....39
4.2.2 顫振穩定曲線圖分析.....42
4.2.3 顫振穩定模型與切削實驗結果.....42
4.2.4 刀具磨耗與最低穩定切深之變化.....54
第 五 章 結論與未來展望.....57
參考文獻.....58
Extended Abstract.....61

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