臺灣博碩士論文加值系統

滾珠螺桿為精密線性傳動與定位系統之重要元件，近年來已應用於精密科技產業及精密機械產業的定位及測量系統上。機構作用原理既是將傳統螺桿中的滑動接觸轉換成滾動接觸，也讓螺桿帽座內的鋼珠介於螺帽與螺桿間做出迴轉運動而轉換為直線運動之傳動機械組件。在裝配滾珠螺桿時零組件之間因幾何干涉而產生的接觸壓力相對於運動性能影響甚多，如果內部滾珠受到適當的壓應力且與螺桿軸、螺桿帽座相對應配合之哥德式溝槽有良好公差適配性時就能得到最完美的轉換效率，且擁有一定機構自鎖性並降低使用機構時異常的震動及惱人的噪音。
因此本研究主要探討，以不改變操作設備的習慣及相關設置下滾珠螺桿經過CNC數控銑床不堪使用後，紀錄滾珠螺桿更換週期。結合應用有限元素法以COMSOL Multiphysics軟體對滾珠螺桿內部滾珠與螺桿帽座和螺桿軸上之哥德式溝槽作預負荷應力分析，模擬後結果再加上記錄上新品預壓扭矩(Drag Torque)、滾珠螺桿更換週期以及實際使用狀況顯示之更換前後軸向負載進行相關的計算分析，進一步在統計學相關的計算出平均值、標準差及變異數後進行探討產生結論。在日後須改良的參考依據為目標，以達到更具高效益、高競爭力產品。
本研究最後的結果得知滾珠螺桿應力分析中滾珠上的接觸點，因為接觸面積小造成受力集中產生最大應力點，觀察後容易損壞零件關鍵因子為滾珠而其表面應力值約為13.9467Kpa。滾珠螺桿的更換紀錄延伸計算出滾珠螺桿平均使用日數為1201.18日(天)數換言之使用周期約為3.29年，以及實驗設備上軸向移動負載表顯示出伺服馬達驅動中相對於馬達的抵抗阻力，其單位以百分比表示記錄下實際使用狀況並計算發生的平均故障負載(Yibar)5.1364%與平均修復負載(Yjbar)12.9091%。再依據實際滾珠螺桿內鋼珠磨損狀況量測對比滾珠螺桿規格表中鋼珠尺寸做磨耗損失計算得出滾珠磨損磨耗量Wear為0.00031mm3。從修復前後軸向移動負載率差異與滾珠磨損磨耗量的計算中瞭解到隨著滾珠螺桿使用時預壓扭矩(Drag Torque)連同軸向移動負載會逐漸地降低，導致滾珠螺桿上負責讓螺桿軸的旋轉運動轉換成直線運動之螺桿帽座毫無自鎖性質，其轉換媒介中滾珠磨耗損失會造成間隙而讓轉換運動效益下降，使得伺服馬達不易控制軸向移動和定位而影響CNC銑床機械加工。

Ball screw is an important component of precision linear transmission and positioning system, which has been used in positioning and measuring systems of precision science and technology industry and precision machinery industry in recent years. The mechanism action principle is not only to convert the sliding contact in the traditional screw into rolling contact, but also to make the steel ball in the screw cap seat between the nut and the screw to make rotary motion and convert it into linear motion. When assembling the ball screw, the contact pressure between components due to geometric interference has a great influence on the motion performance. If the internal ball is subjected to appropriate compressive stress and the Gothic groove matched with the screw shaft and screw cap has good tolerance adaptability, the most perfect conversion efficiency can be obtained, and the mechanism has certain self-locking property and reduces abnormal vibration and annoying noise when using the mechanism.
Therefore, this study mainly discusses, in order not to change the habit of operating equipment and related settings, after the ball screw passes through the CNC milling machine, the replacement cycle of the ball screw is recorded. Combined with the finite element method and COMSOL Multiphysics software, the preload stress analysis of the ball inside the ball screw, the Gothic groove on the screw cap seat and the screw shaft was carried out. The simulation results, together with the recorded calculation and analysis of the Drag Torque of the new product, the replacement cycle of the ball screw and the axial load before and after the replacement according to the actual service condition, further discussed and reached a conclusion after statistically calculating the average value, standard deviation and variance. In the future, it is necessary to improve the reference basis as the goal, so as to achieve more efficient and competitive products.
The final results of this study show that the contact point on the ball in the stress analysis of the ball screw has the maximum stress point due to the stress concentration caused by the small contact area. After observation, the key factor that is easy to damage the parts is the ball, and its surface stress value is about 13.9467Kpa. The replacement record extension of the ball screw calculates that the average service days of the ball screw are 1201.18 days (days), in other words, the service cycle is about 3.29 years, and the axial moving load table on the experimental equipment shows the resistance relative to the motor in the servo motor drive, which is expressed in percentage. Record the actual service conditions and calculate the average failure load (yibar) 5.1364% and average repair load (yjbar) 12.9091%. Then, according to the measurement of the steel ball wear in the actual ball screw, the wear loss is calculated by comparing the steel ball size in the ball screw specification table, and the ball wear is 0.00031mm3. From the calculation of the axial movement load rate difference and ball wear before and after repair, it is learned that the preload torque and axial movement load will gradually decrease with the use of the ball screw, resulting in no self-locking property of the screw cap seat on the ball screw responsible for converting the rotational motion of the screw shaft into linear motion, The loss of ball wear in the conversion medium will cause clearance and reduce the efficiency of conversion movement, which makes it difficult for the servo motor to control axial movement and positioning and affect the machining of CNC milling machine.

摘要 ………………………………………………………………………………i
Abstract…………………………………………………………………………iii
誌謝 ………………………………………………………………………………v
目錄 ……………………………………………………………………………vi
表目錄 ………………………………………………………………………viii
圖目錄 ……………………………………………………………………………ix
符號說明……………………………………………………………………………xi
第一章 緒論……………………………………………………………………1
1.1 研究動機與目的……………………………………………1
1.2 文獻回顧…………………………………………………… 1
1.3 研究範圍與限制……………………………………………2
1.4 研究流程…………………………………………………… 2
1.5 論文架構…………………………………………………… 3
第二章 滾珠螺桿………………………………………………………4
2.1 機構特性…………………………………………………… 4
2.2 螺桿構造…………………………………………………… 6
2.2.1 循環方式…………………………………………………… 6
2.2.2 預壓方式…………………………………………………… 9
2.3 導程精度…………………………………………………… 11
第三章 研究規劃…………………………………………………………13
3.1 研究目的…………………………………………………… 13
3.2 實驗測試件規格………………………………………14
3.2.1 實驗測試件…………………………………………………. 14
3.2.2 滾珠螺桿潤滑油特性…………………………………17
3.3 實驗步驟流程……………………………………………… 19
第四章 測試設備及步驟…………………………………………20
4.1 實驗設備簡介……………………………………………20
4.2 實驗滾珠螺桿……………………………………………22
4.2.1 實驗軸向選擇…………………………………………………22
4.2.2 實驗滾珠螺桿配置及安裝…………………………25
第五章 模擬分析與計算結果……………………………29
5.1 COMSOL Multiphysics軟體簡介…29
5.2 COMSOL Multiphysics應力分析…29
5.3 相關資料分析……………………………………………36
第六章 結論………………………………………………………………44
6.1 結論…………………………………………………………………………44
6.2 建議…………………………………………………………………………44
參考文獻 …………………………………………………………………………………46
附錄一 日本THK滾珠螺桿摩擦係數………………………49
附錄二 日本THK滾珠螺桿型式………………………………50
附錄三 日本THK滾珠螺桿的精度…………………………53
附錄四 日本THK滾珠螺桿安裝步驟……………………55
附錄五 滾珠螺桿規格表……………………………………………57
Extended Abstract…………………………………………………………58

[1]莊瀅芯，2019，“滾珠螺桿產業現況與發展趨勢”，機械工業雜誌， 430期，頁41∼42，1月。
[2] R. H.TURNER, G. SWEENEY, 1967, "Some problems associated
with the development of ball screw and ball nut grinding machines",
International Journal of Machine Tool Design and Research,
volume 7, issue 4, pp. 406-429, December.
[3] D. Spath, J. Rosum, A. Haberkern, 1995, " Kinematics, Frictional
Characteristics and Wear Reduction by PVD Coating on Ball Screw
Drives", CIRP Annals, volume 44, issue 1, pp. 349-352, January.
[4] Chun-Jen Chen, Wenyuh Jywe , Yu-Chun Liu , Hsin-Hong Jwo,2011,
" The Development of using the digital projection method to measure
the contact angle of ball screw", Physics Procedia, volume 19,
pp. 36-42, August.
[5] D. Olaru, G. C. Puiu, L. C. Balan, V. Puiu, 2004, " A new model to
estimate friction torque in a ball screw system", Product Engineering,
pp. 333-346, August.
[6] A. Dadalau, M. Mottahedi, K. Groh, A. Verl, 2010, "Parametric
modeling of ball screw spindles", Product Engineering, pp. 625-631,
August.
[7] Romuald Bertolaso, Mohammed Cheikh, Yoann Barranger,
Jean-Christophe Dupré, Arnaud Germaneau, Pascal Doumalin, 2014,
"Experimental and numerical study of the load distribution in a ball-
screw system", Journal of Mechanical Science and Technology,
volume 28, issue 4, pp. 1411-1420, November.
[8] A. Garinei, R. Marsili, 2012, " A new diagnostic technique for ball
screw actuators", Measurement, volume 45, pp. 819-828, March.
[9] Jerzy Z. Sobolewski, 2012, " Vibration of the ball screw drive",
Engineering Failure Analysis, volume 24, pp. 1-8, March.
[10] A.Verl, S.Frey, 2010, "Correlation between feed velocity and
preloading in ball screw drives", CIRP Annals – Manufacturing
Technology, volume 59, issue 1, pp. 429-432, April.
[11] Shyh-Chour Huang, 1995, "Analysis of a model to forecast thermal
deformation of ball screw feed drive systems", International Journal
of Machine Tools and Manufacture, volume 35, issue 8,
pp. 1099-1104, August.
[12] Guo-Hua Feng, Yi-Lu Pan, 2012, "Investigation of ball screw
preload variation based on dynamic modeling of a preload adjustable feed
drive system and spectrum analysis of ball-nuts sensed vibration signals",
International Journal of Machine Tools and Manufacture,volume 52, pp. 85-96,
September.
[13]魏進忠，2003，“單螺帽雙圈滾珠螺桿在預負荷及潤滑作用條件下運動
機制與機械性能的理論分析及實驗印證”，國立成功大學機械工程學系 博士論文。
[14] Chin Chung Wei, Jen Fin Lin, Jeng-Haur Horng, 2009, "Analysis of
a ball screw with a preload and lubrication ",Tribology International,
volume 42, issue 11-12, pp. 1816-1831, December.
[15]劉志宏，2011，“高速滾珠螺桿振動響應與扭矩分析”，國立虎尾科技
大學機械與機電工程研究所碩士論文。
[16]陳政傳，1998，“滾珠螺桿振動及機械效率之理論及實驗分析”，國立
成功大學機械工程學系碩士論文。
[17]彭唯耕，2018，“單螺帽滾珠螺桿之準靜態分析與動態分析”，國立成
功大學機械工程學系碩士論文。
[18]吳建儒，2009，“高速高負載滾珠螺桿性能模擬分析”，國立虎尾科技
大學機械與機電工程研究所碩士論文。
[19]曹博涵，2005，“滾珠螺桿預壓力、軸向剛性與尺寸及公差關係之探
討”，國立中興大學機械工程學系所碩士論文。
[20]王永欣，2012，“應用類神經網路於滾珠螺桿之定位與行程分析”，國
立虎尾科技大學機械與機電工程研究所碩士論文。
[21]王昭鵬，2019，“運用田口實驗方法於滾珠螺桿接觸角與運動順暢度之
研究”，國立中興大學機械工程學系所碩士論文。
[22]劉育君，2008，“以數位投影法測量滾珠螺桿哥德式螺紋接觸角之研
究”，國立虎尾科技大學機械與機電工程研究所碩士論文。
[23]林勇學，2009，“承受預壓力之滾珠螺桿有限元素分析”，逢甲大學機
械工程學所碩士論文。
[24]潘奕呂，2011，“內嵌式滾珠螺桿感測系統及其應用於螺桿預壓之研
究”，國立中正大學工學院機械工程學系碩士論文。
[25]羅凱鴻，2011，“滾珠螺桿預壓之偵測”，國立中正大學工學院機械工
程學系碩士論文。
[26]陳一愷，2020，“基於預壓感測器對雙螺帽式滾珠螺桿系統之故障診
斷”，國立成功大學機械工程學系碩士論文。
[27]康晉瑋，2020，“加大滾珠預壓與偏移式預壓滾珠螺桿在垂直傳動之傳
動特性量測與分析”，國立虎尾科技大學機械與機電工程研究所碩士論文。
[28]夏仲秋，2020，“滾珠螺桿之運動靜力分析”，崑山科技大學機械工程
研究所碩士論文。
[29]上銀科技股份有限公司，上銀滾珠螺桿技術手冊。