臺灣博碩士論文加值系統

近年來科技的進步促進工業快速發展，因此製造業競爭愈加激烈，在大量生產的情況下製造成本為目前重要的議題，而切削加工生產中最需要的重要環節，特別是航太、汽車工業甚至是半導體產業極其重要，目前國內對於CNC銑床所使用端銑刀具的更換時機，大多以人的經驗法則進行判斷，面對各方面不同切削材料之刀具磨耗情形也有所不同，因此經驗法則的可靠性也會降低許多，故對於現今多變的加工來說已無法負荷，導致端銑刀具的磨耗有諸多因素，如不同的切削參數、切削力量、切削劑與切削熱等，特別是運用於難切削材的刀具磨耗程度更為嚴重，本研究以分析切削刀具與材料特性，應用品質設計之田口法探討三把不同材質之端銑刀具，分別為未鍍層高速鋼刀、刀具表面附著AlTi鍍層鎢鋼刀與刀具表面附著AlCr2O3鍍層鎢鋼刀，以沃斯田鐵系304不銹鋼作為本實驗切削材料，分別對刀具磨耗、工件表面粗糙度與切削後槽寬的變化之影響趨勢。研究主要分為兩大部分，其一為切削及刀具材料實驗分析，透過SEM/EDS與XRD儀器對304不鏽鋼材料與三把不同材質之端銑刀具進行材料特性分析，並利用洛氏硬度試驗機、微小維克氏硬度試驗機、拉伸試驗、非接觸式表面粗糙度量測儀等，探討切削材料及刀具機械性質。其二為切削品質設計與刀具磨耗分析，應用品質設計之田口方法以四個實驗因子與三種水準進行L9直交表排列組合，針對不同材質之端銑刀具特性對沃斯田鐵系304不鏽鋼材料進行加工實驗規劃與刀具磨耗量測，皆參照ISO8688-2規範以工具顯微鏡5X倍率量測底刃(Land)及側刃(Flank)部位磨耗變化，並利用ANOVA分析結果可得知影響刀具磨耗、工件表面粗糙度與切削後槽寬的變化之實驗因子。

In recent years, the progress of science and technology has promoted the rapid development of industry, so the competition in the manufacturing industry has become more and more fierce, and the manufacturing cost in the case of mass production is an important issue at present, and the most needed important links in cutting production, especially the aerospace, automotive industry and even the semiconductor industry are extremely important. Recently, the method that has been frequently employed to predict the replacement timing of end milling tool in CNC machines is based on the experience of the experts. However, the wear situation of tools with different materials vary in several aspects. Thus, it increases the difficulty in producing products with a consistent quality as different experts may impose different decision making during the process, such as the used of cutting parameters, tools and heat control techniques. In addition, the method is not suitable for processing products with complex cutting parameters especially product with high durability due to the consistent requirement of decision making by the domain experts and the resulting severities of wear conditions of the tool. In this research, three end milling tools with different materials were analyzed and discussed on the characteristics and materials of the tool. Taguchi method of quality design has been employed to conduct a systematic experiment to investigate the effect of tool materials and machining parameters on the workpiece. The tool materials are the uncoated HSS (High Speed Steel, HSS), AlTi-coated tungsten steel, and AlCr2O3- coated tungsten, whereas workpiece material is 304 stainless steel. Resulting variables observed are the changes of tool wear, surface roughness of workpiece and the width of groove. The research consists of two major part, which is the experimental analysis on material characteristics of the tool and workpiece, and design of experiments for parameters optimization. In the experimental analysis, SEM/EDS (Energy-dispersive X-ray spectroscopy, EDS） and XRD (X-ray Diffraction, XRD) have been used to observe the surface properties of tools and workpieces. Besides that, Rockwell hardness, Vickers hardness, non-contact surface roughness and tensile test have been employed to measure the mechanical properties of tools and workpieces. For the optimization of quality in the milling process, Taguchi method is used to design an experiment to investigate the wear of tool on 304 stainless steel workpiece by using a L9 orthogonal table with four factors and three control level. The wear changes in land and flanks were measured at 5 times magnification using a microscope in reference to the ISO8688-2 specification. The critical factors that affect the tool wear, surface roughness of workpiece and groove width can be obtained through the ANOVA analysis.

摘要........................................i
Abstract...................................ii
誌謝.......................................iv
目錄........................................v
表目錄.....................................vii
圖目錄.....................................viii
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 國內外影響刀具磨耗之實驗因子的相關研究.....3
第 三 章 研究架構與方法......................10
3.1 研究架構與流程..........................10
3.2切削及刀具材料實驗分析....................10
3.2.1切削實驗機台與刀具材料..................11
3.2.2材料特性分析儀.........................12
3.3切削品質設計與刀具磨耗分析................21
3.3.1實驗設計之田口法.......................21
3.3.2品質損失函數...........................22
3.3.3銑床切削參數與經驗公式..................24
3.3.4加工參數對刀具磨耗之影響................25
第 四 章 實驗結果...........................27
4.1切削及刀具材料實驗分析結果................28
4.1.1切削材料及刀具材料特性分析..............28
4.1.2切削材料及刀具硬度試驗分析結果..........33
4.1.3切削材料之拉伸實驗分析結果..............37
4.2切削品質設計與刀具磨耗分析結果............40
4.2.1實驗因子設計與刀具磨耗實驗..............40
4.2.3端銑刀具磨耗與工件表面粗糙度之量測結果...42
4.3.1 ANOVA分析結果........................44
第 五 章 結論與未來展望.....................47
參考文獻...................................48
Extended Abstract.........................50

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