臺灣博碩士論文加值系統

近年來金屬積層製造(Additive Manufacture; AM)發展迅速，其優點能在短時間
內製造出複雜特殊結構或少量客製工件，應用於模具產業更能提供無可取代的內
流道及功能梯度金屬等技術。但金屬積層的成品表面粗糙，需經後處理程序。本
實驗研究採多道次放電加工對金屬積層材進行表面處理，並藉正極性及搖動放電
加工使積層模仁獲良好的面粗度及表面質量。本文發現依億曜放電加工手冊執行
多道次加工其工序繁雜耗時且最後完成面會有惡化的現象；因此，初步實驗規畫
以至少移除再鑄層兩倍及三倍厚度為原則精簡加工深度裕量，再依表面粗度、再
鑄層厚度及加工時間進行加工道次縮減。
首先根據表面粗度及再鑄層厚度進行加工裕量縮減，總加工深度從1.588 mm
縮減至0.519 mm 縮減幅度達67%，表面粗度達Ra 0.17μm，使總加工時間約減少
約11.4 小時，效率提升約77%。其次，根據粗度的改善率再縮減四個道次，加工
裕量再減少0.106 mm，使加工總時間再減少為1 小時37 分效率提升52%，表面粗
糙度達Ra 0.2μm m，再鑄層厚約2.37μm，而提出適用於AM CORRAX 積層模仁
之新版放電工序。最後，進行AM CORRAX 與原始CORRAX 材的放電加工比較，
實驗結果顯示前者表面粗度略高0.02μm 而再鑄層厚幾乎不變，且兩種材料在進行
正極性搖動加工前再鑄層呈現厚薄不均，在正極性後則呈現明顯薄化而均勻。此
外，兩材料放電加工裂紋皆僅留存於再鑄層上而不致延伸進入母材。

In recent years, Metal lamination Additive Manufacture (AM) has developed rapidly. Its
advantages can produce not only complex structures or a small lot of custom-made
pieces in a short time but also provide irreplaceable internal runners and functional
grade metals in the mold industry. However, the surface of the finished AM lamination
metal is rough, and it usually needs post-processing. In this research, both multi-pass
electrical discharge machining (EDM) and the combination of reverse polarity with
orbital EDM at the final finishing are adopted to obtain a good surface quality. It is
found that EDM processes according to manual of the original machine builder for steel
is complicated and time- consuming, and even the final finish surface deteriorates again.
Therefore, the preliminary experimental plan is to reduce the machining depth margin
by a principle of removing three times the thickness of the recast layer and then to
reduce the processes according to the change rates of the surface roughness and the
recast layer thickness.
First of all, the depth margin of each process is reduced according to the thickness of the
recast layer and the surface roughness. The total processing depth is reduced from 1.588
mm to 0.519 mm. The reduction rate is 67%, and achieve the surface roughness achieve
to 0.2μm, which reduces the total processing time by about 11.4 hours or increases 77%
of Efficiency. Secondly, four of the EDM passes are further reduced according to the
change rate of surface quality. Then, the machining depth margin is reduced further by
0.106 mm, and the total EDM time is reduced to 1 hr and 37 min. The efficiency is
increased by 52%, the surface roughness achieves 0.2μm with the thickness of the recast
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layer reaches about 4 μm. This thesis provides a new version of EDM process-planning
for the AM CORRAX steel mold. Finally, verification by comparing the EDM of AM
CORRAX steel and the original CORRAX cast alloy bulk steel is conducted.
Experimental results reveal that the former has a slightly higher surface roughness of
0.02 μm and the thickness of the recast layer is almost the same. The recast layer thick
of both materials is uneven before the reverse polarity process, and it is obviously
thinner and more uniform after the reverse polarity. In addition, the EDM cracks of the
two materials are only remained on the recast layer and never extend into the material
substrate.

摘要 ...................................................................................................................................... IV
ABSTRACT ............................................................................................................................ V
致謝 ..................................................................................................................................... VII
目錄 .................................................................................................................................... VIII
表目錄 .................................................................................................................................... X
圖目錄 .................................................................................................................................. XI
符號說明 ............................................................................................................................ XV
第1 章 緒論 ......................................................................................................................... 1
1.1 前言 ............................................................................................................................. 1
1.2 文獻回顧 .................................................................................................................... 2
1.3 研究動機 ...................................................................................................................10
1.4 論文架構 ...................................................................................................................10
第2 章 加工原理 ................................................................................................................12
2.1 放電加工 ...................................................................................................................12
2.1.1 放電加工基本原理 ...........................................................................................12
2.1.2 放電加工參數 ....................................................................................................12
2.2 行星式搖動放電加工 ..............................................................................................15
2.3 放電加工道次規劃原理 ..........................................................................................15
2.4 金屬積層製造 ...........................................................................................................17
第3 章 實驗設備與方法 ...................................................................................................20
3.1 實驗設備 ...................................................................................................................20
3.1.1 放電加工機 ........................................................................................................20
3.1.2 線切割放電加工機 ...........................................................................................21
3.1.3 EOS 金屬雷射燒結設備 ....................................................................................23
3.1.4 雷射共軛焦顯微鏡 ...........................................................................................25
3.1.5 表面粗度儀 ........................................................................................................26
3.1.6 超音波清洗機 ....................................................................................................27
3.1.7 光學顯微鏡 ........................................................................................................27
3.1.8 研磨拋光機 ........................................................................................................28
3.1.9 手動鑲埋機 ........................................................................................................29
ix
3.2 實驗材料 ...................................................................................................................30
3.2.1 金屬積層材料 ....................................................................................................30
3.2.2 電極 ....................................................................................................................32
3.3 實驗方法 ...................................................................................................................34
3.4 實驗流程 ...................................................................................................................38
第4 章 加工深度裕量縮減實驗 .......................................................................................41
4.1 初步實驗 ...................................................................................................................41
4.1.1 表面粗度與表面形貌 .......................................................................................41
4.1.2 再鑄層 ................................................................................................................49
4.1.3 放電加工裂紋 ....................................................................................................54
4.1.1 加工時間 ............................................................................................................57
4.2 二次實驗(縮減加工深度) ........................................................................................58
4.2.1 表面粗度與表面形貌 .......................................................................................59
4.2.2 再鑄層及裂紋 ....................................................................................................68
4.2.3 加工時間 ............................................................................................................70
4.2.4 本節小結 ............................................................................................................71
第5 章 EDM 道次縮減實驗及原鑄造材料比較.............................................................72
5.1 放電道次縮減實驗 ...................................................................................................72
5.1.1 表面粗度與表面形貌 .......................................................................................73
5.1.2 再鑄層與裂紋 ....................................................................................................76
5.1.3 加工時間 ............................................................................................................78
5.1.4 1. 本章小結 ........................................................................................................79
5.2 與鑄造CORRAX 之比較.........................................................................................79
5.2.1 表面粗度與表面形貌 .......................................................................................80
5.2.2 再鑄層與裂紋 ....................................................................................................83
5.2.3 加工時間 ............................................................................................................86
5.2.4 本章小結 ............................................................................................................91
第6 章 -結論 .......................................................................................................................92
第7 章 參考文獻 ................................................................................................................94
附錄: ......................................................................................................................................96

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