本研究主要針對孔徑500 μm之Ti-6Al-4V加工特徵形貌和精度缺陷進行改善，提出一套磁力輔助電化學磨料噴射複合加工技術。期望藉由磁力披覆一具厚度之犧牲層於工件表面，以改善過往加工上所遇到加工孔緣產生不規則導角或濺射等問題。研究先由電化學噴射加工實驗發現在電解液濃度比例NaNO3 50 %時，容易於試片孔底快速形成白色生成物(Ti(OH)4)，因生成物的高阻抗性與不規則輪廓，容易導致無法持續電化學加工及造成噴流場產生隨機濺射現象，致使孔底形成不規則輪廓及擴孔量增加等缺陷。為此，研究持續利用電化學噴射加工法以添加研磨粒方式進行改善，由實驗結果得知在相同加工條件下，當電化學噴射加工法添加研磨粒時，可透過研磨粒對工件表面高速撞擊形成之磨削作用，可即時移除Ti-6Al-4V於電化學加工所形成的氧化層，使電化學反應更為穩定，同時獲得較佳加工效率與輪廓特徵，但工件入口處仍然存在些少量導角與擴孔等缺陷。因此研究導入磁力輔助電化學磨料噴射加工法，由實驗發現隨著加工持續進行，研磨粒與導磁粒子會隨孔徑變化而形成不同厚度的犧牲層，使研磨粒高速撞擊工件時，會形成直接與間接磨削作用，同時得知當導磁粒子添加比例為0.250 wt%時。其孔徑尺寸約828 μm與加工深度約190 μm明顯優於添加比例0.125 wt%與0.500 wt%。其加工後可獲得3.83 μmSa表面精度，相較於電化學磨料噴射加工後表面5.02 μmSa，改善幅度23.71 %。最後研究將所得3種電化學加工法最適參數條件分別進行加工效率實驗，由實驗得知3種電化學加工法加工效率皆在27.8 μm/s至33.3 μm/s之間，但磁力輔助電化學磨料噴射法可獲得明顯加工擴孔量與雜散腐蝕改善效果，證明透過磁力輔助電化學磨料噴射加工法，可有效降低擴孔量與提升形貌特徵精度。未來可作為相關產業另一種新型複合加工法參考。

The present study focuses on the improvement of Ti-6Al-4V Morphology and Precision defects. A set of Magnetic-assisted Electrochemical abrasive slurry jet machining is proposed to magnetically coat a sacrificial layer of a certain thickness on the surface of the workpiece. It is used to improve the problems encountered in past machining, such as irregular lead angle or sputtering at the edge of the machined hole. Research first found through electrochemical jet machining experiments that when the electrolyte concentration ratio is 50 % NaNO₃. It is easy to form a white product (Ti(OH)4) on the bottom of the hole of the specimen. Continuous electrochemical processing is easy to prevent because of the product's irregular contour and high impedance. This makes it impossible to continue electrochemical processing and causes random sputtering of the jet. Defects such as irregular contours and increased hole enlargement are formed at the bottom of the hole. For this reason, the study was carried out by adding abrasive particles to the electrochemical jet machining method to improve the process. The experimental results show that under the same processing conditions. When abrasive particles are added to the electrochemical jet machining method, the workpiece can be improved by adding abrasive particles. The grinding effect can be formed by the high-speed impact of abrasive grains on the surface of the workpiece. The oxidized layer formed by Ti-6Al-4V in the electrochemical machining process can be removed immediately, making the electrochemical reaction more stable. At the same time, better machining efficiency and contour characteristics are achieved. However, there are still a few defects, such as lead angle and hole enlargement at the entrance of the workpiece. Therefore, the magnetic-assisted electrochemical abrasive jet machining method was investigated. From the experiment, it is found that as the processing continues. The abrasive and magnetizing particles will form a sacrificial layer of different thicknesses with the change in hole diameter. So that when the abrasive particles hit the workpiece at high speed. Formation of direct and indirect grinding effect. At the same time, it is known that when the proportion of magnetizing particles added is 0.25 wt%. The aperture size of about 828 μm and processing depth of about 190 μm is significantly better than the addition ratio of 0.13 wt% and 0.50 wt%. The surface accuracy of 3.83 μmSa can be obtained after machining. Compared with the surface accuracy of 5.02 μmSa after electrochemical abrasive blasting, the improvement was 23.71 %. Finally, the machining efficiency of the three electrochemical machining methods was investigated under the optimum parameter conditions. It was found that the machining efficiency of the three electrochemical machining methods ranged from 27.778 μm/s to 33.333 μm/s. However, the magnetic-assisted electrochemical abrasive spraying method can significantly improve the amount of hole enlargement and stray corrosion. This proves that the magnetically assisted electrochemical abrasive jetting process can effectively reduce the amount of porosity and improve corrosion. It can effectively reduce the amount of hole enlargement and improve the accuracy of topographic features. It can be used as another new compound processing method for reference in related industries.

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..........................................................1
1.2 動機與目的........................................................4
1.3 論文架構..........................................................4
1.4 整體研究流程......................................................5
第二章 文獻回顧........................................................6
2.1 鈦合金加工技術與應用...............................................6
2.2 電化學噴射加工技術與應用............................................8
2.3 磨料噴射加工技術與應用............................................10
2.4 電化學磨料噴射加工技術與應用.......................................11
2.5 磁力輔助加工技術與應用............................................12
2.6 實驗計劃法與應用..................................................13
第三章 實驗設備與材料.................................................14
3.1 實驗設備.........................................................14
3.1.1 可程式電化學複合加工系統.........................................14
3.1.2 直流電源供應器..................................................16
3.1.3 超音波清洗機...................................................17
3.1.4 3D列印機......................................................17
3.2 量測設備.........................................................18
3.2.1 白光干涉儀.....................................................18
3.2.2 pH /電導度計..................................................18
3.2.3 熱場發型掃描式電子顯微鏡.........................................19
3.2.4 CCD顯微量測系統...............................................19
3.2.5 特斯拉計.......................................................20
3.3 實驗材料.........................................................21
3.3.1 實驗試片.......................................................21
3.3.2 噴嘴電極.......................................................21
3.3.3 電解液.........................................................22
3.3.4 研磨粒子.......................................................23
3.3.5 導磁粒子.......................................................24
3.3.6 N35釹鐵硼磁體.................................................25
第四章 研究方法.......................................................26
4.1 電化學加工原理....................................................26
4.1.1 法拉第定律.....................................................26
4.1.2 電流密度.......................................................27
4.1.3 歐姆定律.......................................................27
4.2 電化學噴射加工法..................................................27
4.3 電化學磨料噴射加工法..............................................28
4.4 磁力輔助電化學磨料噴射加工法.......................................29
4.5 實驗設計法.......................................................30
4.6 各實驗流程.......................................................33
4.6.1 實驗前處理與操作步驟............................................37
第五章 結果與討論.....................................................38
5.1 電化學噴射加工對Ti-6Al-4V加工形貌特徵之影響........................38
5.1.1 電化學噴射加工最適參數條件分析...................................38
5.1.2 驗證實驗.......................................................45
5.2 電化學磨料噴射加工對Ti-6Al-4V微孔形貌特徵之影響.....................46
5.2.1 電化學磨料噴射加工最適參數條件分析...............................47
5.2.2 電化學磨料噴射加工驗證實驗.......................................48
5.2.3 研磨粒添加效果..................................................53
5.3 磁力輔助電化學磨料噴射加工對Ti-6Al-4V加工形貌特徵之影響..............56
5.3.1 導磁粒子添加比例分析............................................56
5.3.2 磁場設置距離分析................................................59
5.3.3 磁力輔助加工效果分析............................................61
5.3.4 加工效率分析...................................................63
第六章 結論與未來展望.................................................66
6.1 結論.............................................................66
6.2 未來展望.........................................................67
參考文獻 ............................................................68
Extended Abstract...................................................76

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