臺灣博碩士論文加值系統

摘要 I
Abstract II
誌謝 IV
目錄 V
圖目錄 IX
表目錄 XVI
符號說明 XVIII
第1章 緒論 1
1.1 前言 1
1.2 文獻回顧 3
1.2.1 實心電極放電加工 3
1.2.2 中心出水、抽吸管狀電極放電加工 6
1.2.3 快速成形製造電極放電加工 12
1.2.4 銅合金雷射金屬積層製造 13
1.3 研究動機與目的 16
1.4 本文架構 17
第2章 加工原理介紹 18
2.1 放電加工 18
2.1.1 放電加工原理 18
2.1.2 放電加工材料去除機制 19
2.1.3 放電加工參數 21
2.1.4 沖流機制 23
2.1.5 管電極加工特性-中心出水 25
2.2 金屬積層製造 27
2.3 電沉積銅層 28
2.4 有限元素分析 29
第3章 實驗設備與實驗裝置、流程設計 30
3.1 實驗設備 30
3.1.1 雕模放電機工機 30
3.1.2 金屬3D列印機 31
3.1.3 線切割加工機 32
3.1.4 示波器 34
3.1.5 電流測試槍 34
3.1.6 差動測試棒 35
3.1.7 超音波清洗機 37
3.1.8 雷射共軛焦顯微鏡 37
3.1.9 表面輪廓儀 38
3.1.10 金屬導電率量測儀 38
3.1.11 水質檢測器 39
3.1.12 電子天平 39
3.2 實驗材料 40
3.2.1 電極 40
3.2.2 工件 44
3.3 實驗方法與規劃 45
3.3.1 CAE模擬中心出水流場與排渣模型 45
3.3.2 實驗設置-模擬深孔中放電排渣效率 46
3.3.3 模擬深孔中放電排渣效率之實驗設置 48
3.3.4 刀具電極之幾何形狀設計 48
3.3.5 中心出水夾治具設計 52
3.4 量測方法 55
3.4.1 材料移除率 55
3.4.2 電極消耗率 55
3.4.3 表面粗糙度 55
3.4.4 側邊錐度 55
3.4.5 深孔底部與角隅形貌 55
3.5 實驗流程 56
第4章 CFD流場與顆粒排渣模擬分析 58
4.1 CFD初步流場模擬分析 58
4.1.1 實心電極採側邊沖流 59
4.1.2 直通管電極採中心出水 62
4.1.3 直通管電極模擬抬刀高度 63
4.1.4 斜通管電極採中心出水 66
4.1.5 螺旋水道電極採中心出水 68
4.1.6 螺旋水道電極模擬抬刀高度 71
4.1.7 旋轉輔助直、斜通管、螺旋水道電極 73
4.1.8 雙螺旋水道電極 78
4.1.9 抬刀高度顆粒流動路徑-直通管與螺旋水道電極 80
4.1.10 小結 82
4.2 模擬各式刀具顆粒排出與殘留之分析 83
4.2.1 直通管刀具電極 83
4.2.2 斜通管電極+旋轉60rpm 84
4.2.3 單螺旋水道電極 86
4.2.4 單螺旋水道電極+外部導流槽 88
4.2.5 單螺旋水道電極+旋轉60rpm 89
4.2.6 雙螺旋水道電極 89
4.2.7 排渣效率 91
4.2.8 小結 95
4.3 各式電極於抬刀高度之顆粒殘留分析 96
4.3.1 抬刀高度影響 96
4.3.2 加工深度影響 99
4.3.3 排渣效率 101
4.3.4 小結 104
第5章 積層製造刀具電極放電加工實驗 105
5.1 各製程刀具電極之比較 105
5.1.1 電鍍銅 105
5.1.2 電鑄銅 107
5.1.3 銅-鉻-鈮合金 110
5.2 比較中心出水電極之沖流效益 118
5.2.1 直通管電極無旋轉輔助EDM 118
5.2.2 直通管電極旋轉輔助EDM 120
5.2.3 螺旋水道電極無旋轉輔助EDM 121
5.2.4 螺旋水道電極旋轉輔助EDM 122
5.2.5 雙螺旋水道電極EDM 123
5.3 模擬深孔放電排渣電導度量測 124
5.3.1 導程角度對排渣效率之影響 124
5.3.2 抬刀高度對排渣效率之影響 126
5.4 螺旋水道電極設計對流量之影響 127
5.4.1 螺旋水道長度對流量之影響 127
5.4.2 流量大小對加工效率之影響 128
5.4.3 流量大小對工件形貌之影響 130
5.5 螺旋水道電極盲孔放電形貌 132
5.5.1 5mm深加工+套20mm高試管-電鑄銅 132
5.5.2 10mm深加工 – AM銅合金電極 137
5.5.3 15mm深加工 – AM銅合金電極 140
5.5.4 盲孔加工材料移除與電極損耗分析 144
5.6 深孔加工效率與穩定度分析 146
5.6.1 初步深孔放電加工 – 紅銅實心與直通管電極 147
5.6.2 深孔放電加工25mm - AM銅合金直通管與螺旋水道電極 149
5.7導流槽與旋轉輔助對放電之影響 – 銅合金直通管電極 153
5.7.1 盲孔15mm深加工形貌討論 153
5.7.2 盲孔加工材料移除與電極損耗分析 158
5.7.3 加工速度分析 160
5.8 小結 162
第6章 結論與未來發展方向 163
6.1 結論 163
6.2 未來發展方向 166
參考文獻 167
作者簡歷 170

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