臺灣博碩士論文加值系統

刀具產業中各家刀具廠在設計刀具幾何角度方面都有各自的「know-how」，然而在設計刀具幾何角度時，通常會依據不同材料的機械性質及切削時的切削參數不同而有所不同。其中刀具幾何角度主要包含楔型角、切削角、離隙角與螺旋角；機械性質主要包含降伏強度、抗拉強度、硬度、剪切強度、導熱係數、楊氏係數、韌性；切削參數主要包含每刃進給、徑向切深。
楔型角會隨著材料的硬度與強度以及切削參數值的增加而加大其角度大小，如此刀具才有足夠的強度抵抗高強度的切削；法向離隙角的設計與材料的楊氏係數及韌性有關，主要避免切削過程中產生回彈導致刀腹面彈破的現象。因此，本論文用8種不同材料(SUJ2、淬火SKD61、NAK80、Ti-6Al-4V、SNCM439、退火SKD61、退火S45C與SUS304)的機械性質設計刀具的楔型角及法向離隙角，在切削過程中尋找刀具楔型角與切削參數之間的關係，切削後使用工具顯微鏡查看刀刃口是否有崩缺或彈破的狀況，再將這8種材料的機械性質與切削參數所對應的刀具楔型角及法向離隙角分別建立數據放入AIM多項式網路。最後驗證方面將五種材料(SKS3、SUS316、S50C、淬火S45C與SCM440)之機械性質及所要使用之切削參數放入預測模型中進行預測，並將預測之角度進行刀具研磨與切削實驗，實驗的結果顯示使用相對應之切削參數切削上述五種驗證材料時，刀腹面都沒有崩缺或被彈破的現象，其刀具楔型角之實際值與AIM模型的預測值誤差皆在±2.3%以內，代表此預測模型有一定的可靠度。

The design of the tool geometry belongs to the know-how of every tool manufacturer and it is based on the mechanical properties of materials and cutting parameters. The tool geometry generally refers to the rake angle, relief angle, and helix angle. The mechanical properties mainly focus on the yield strength, tensile strength, hardness, shear strength, thermal conductivity, Young's modulus, and toughness. The cutting parameters mainly contains feed per tooth and radial depth of cut.
The wedge angle of cutting tools should increase with the gain of hardness and strength of materials to resist the high strength of the material and increase in cutting parameters. The design of the normal relief angle is related to Young's modulus and toughness of the material, mainly to avoid springback effect during the cutting process. In this thesis, the wedge angle and the normal relief angle of the cutting tool were designed according to the mechanical properties of eight different materials (SUJ2, quenched SKD61, NAK80, Ti-6Al-4V, SNCM439, annealed SKD61, annealed S45C, and SUS304). And find the relationship between the wedge angle of the tool and the cutting parameters during the cutting process. After cutting, use the tool microscope to check whether the cutting edge has springback or broken. Then, the mechanical properties of eight materials and the corresponding cutting parameters of the tool wedge angle and normal relief angle are respectively created and data are placed into the Abductory Induction Mechanism (AIM) polynomial network for predictive analysis. To verify the accuracy of the system, data of the cutting parameters to be used and the mechanical properties of five untested materials (SKS3, SUS316L, S50C, quenched S45C, and SCM440) were loaded into the AIM polynomial network for prediction. And the predicted angle is used for tool grinding and cutting test. The experimental results show that using the corresponding cutting parameters to cut five verification materials, the cutting tools have no chipping and springback phenomenon, and the error of the wedge angle between the practical and predicted values is within ±2.3%. This means that the prediction model has a certain degree of reliability.

摘要..............................i
Abstract..............................ii
誌謝..............................iv
目錄..............................v
表目錄..............................viii
圖目錄..............................ix
符號說明 ..............................xiii
第一章 緒論..............................1
1.1 研究背景..............................1
1.2 研究動機與目的..............................1
1.3 文獻回顧..............................2
1.4 研究流程..............................3
1.5 論文架構..............................3
第二章 基礎理論..............................5
2.1 材料與刀具材質特性..............................5
2.1.1 刀具材質特性..............................5
2.1.2 拉伸試驗..............................6
2.1.3 硬度試驗..............................7
2.1.4 剪斷試驗..............................8
2.1.5 衝擊試驗..............................9
2.2 端銑刀具..............................10
2.2.1 端銑刀刃數.............................. 11
2.2.2 端銑刀具刃口與旋向..............................11
2.2.3 端銑刀具幾何角度..............................12
2.2.3.1 徑向切削角..............................13
2.2.3.2 軸向切削角..............................14
2.2.3.3 徑向離隙角..............................14
2.2.3.4 軸向離隙角..............................18
2.2.3.5 螺旋角..............................18
2.3 切削理論..............................18
2.3.1 切削模型..............................19
2.3.2 銑削加工型式..............................22
2.3.2.1 順銑法(climb milling)..............................22
2.3.2.2 逆銑法(conventional milling)..............................22
2.3.3 切削參數..............................23
2.3.3.1 切削力..............................23
2.3.3.2 切線速度 ..............................23
2.3.3.3 每刃進給..............................24
2.3.3.4 徑向切深與軸向切深..............................24
2.4 刀具磨耗..............................24
2.5 類神經網路..............................26
第三章 實驗設備..............................29
3.1 Tool Studio研磨軟體..............................29
3.2 TD-5砂輪修整機..............................30
3.3 HELITRONIC BASIC刀具研磨機..............................31
3.4 KEEJAAN KJ-202 刀具量測儀..............................32
3.5 Zoller genius3s刀具量測儀..............................32
3.6 TAKUMI B8三軸工具機..............................33
3.7 Olympus STM 6高精度工具顯微鏡..............................34
3.8 Abductory Induction Mechanism(AIM)軟體..............................35
第四章 實驗設計與規劃..............................37
4.1 加工測試方法..............................38
4.2 實驗量測方式..............................38
4.2.1 刀刃口狀況..............................39
4.2.2 刀腹磨耗..............................39
4.3 實驗刀具設計..............................39
4.4 切削加工實驗..............................41
4.4.1 改變徑向切深..............................41
4.4.2 改變每刃進給..............................61
4.5 建構實驗數據..............................70
第五章 實驗結果與驗證..............................72
5.1 應用AIM多項式網路..............................72
5.2 驗證模型..............................76
第六章 結論與未來展望..............................89
6.1 結論..............................89
6.2 未來展望..............................89
參考文獻 ..............................90
Extended Abstract..............................92
Abstract..............................92
1.Introduction..............................94
2.AIM polynomial network..............................94
3.Construct primary experimental data..............................95
4.Discussion and Conclusions..............................98
References..............................98

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