臺灣博碩士論文加值系統

帶鋸機有著鋸切範圍大、加工時間短、材料損失少與所花成本較低等優點，使其相較於其他加工方式，常在各領域中做為前端設備。在使用帶鋸機加工過程中，隨著使用時間增加，做為切削刀具的鋸帶其壽命會逐漸減少，使切面歪斜且表面粗糙，造成尺寸的差異影響後續加工。在使用適當的切削參數條件下，除了欲切削工件的幾何尺寸大小之外，不同鋼種的材料成份組成也會產生不同的切削現象，以影響鋸帶的使用壽命以及鋸切工件的品質。
本研究以業界中常使用的304不鏽鋼與S45C中碳鋼兩種鋼材圓棒，使用龍門式帶鋸機進行長時間連續切削實驗，實驗結束條件為材料鋸切至1000刀或是到達1000刀之前鋸帶先行斷裂，分別以進給率20 mm/min、鋸帶速度30 m/min、切削液濃度10 %為切削參數鋸切SUS304不鏽鋼圓棒；進給率60 mm/min、鋸帶速度70 m/min、切削液濃度10 %為切削參數鋸切S45C中碳鋼圓棒，對其兩者進行切削振動、切削負載、鋸切歪斜以及表面粗糙度等分析，討論此兩種不同鋼種之切削磨潤性能差異以及對鋸切訊號分析與進行診斷。
研究結果顯示，因不鏽鋼本身材質軟而韌，且切屑排屑不易之特性，相較於中碳鋼會產生較大的鋸切振動以及鋸切歪斜，而中碳鋼則因硬度較不鏽鋼硬，且有著硬而脆的特性，使其在鋸切過程中產生相較於不鏽鋼較大的切削負載，以及較差的表面粗糙度，以及在關聯性比較下不鏽鋼與中碳鋼在鋸切振動與鋸切負載上都會有著較高的關聯性。

Band saw machines have advantages such as a large cutting range, short processing time, minimal material loss, and lower cost, making them commonly used as front-end equipment in various fields compared to other processing methods. During the process of using a band saw machine, the lifespan of the saw blade, which serves as the cutting tool, gradually decreases with usage time. This leads to skewed cutting surfaces and rough surfaces, resulting in dimensional variations that affect subsequent processing. Under appropriate cutting parameter conditions, in addition to the geometric dimensions of the workpiece, the composition of materials from different steel grades also produces different cutting phenomena, which affect the lifespan of the saw blade and the quality of the cut workpiece.
This study conducted long-term continuous cutting experiments using two commonly used steel materials in the industry: 304 stainless steel and S45C carbon steel round bars. A gantry-type band saw machine was used for the experiments, with the experimental termination conditions set at either 1000 cuts or premature blade breakage before reaching 1000 cuts. The cutting parameters for cutting SUS304 stainless steel round bars were set as a feed rate of 20 mm/min, a blade speed of 30 m/min, and a cutting fluid concentration of 10%. For cutting S45C carbon steel round bars, the cutting parameters were set as a feed rate of 60 mm/min, a blade speed of 70 m/min, and a cutting fluid concentration of 10%. Various analyses were performed on both materials, including cutting vibration, cutting load, sawing deviation, and surface roughness. The study aimed to discuss the differences in cutting tribological performance between these two different steel grades and analyze and diagnose the cutting signals associated with the cutting process.
The research results indicate that stainless steel, due to its soft and ductile nature and the characteristic of chip evacuation, tends to generate higher sawing vibration and sawing deviation compared to medium carbon steel. On the other hand, medium carbon steel, being harder than stainless steel and exhibiting a brittle nature, generates larger cutting loads and poorer surface roughness during the sawing process. Furthermore, in terms of correlation, stainless steel and medium carbon steel show a higher correlation in sawing vibration and sawing load.

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 前言.............................1
1.2 文獻回顧.........................1
1.2.1 鋸切領域相關研究回顧..............1
1.2.2 中碳鋼加工研究回顧................2
1.2.3 不鏽鋼加工研究回顧................2
1.3 研究動機與目的....................3
1.4 論文架構.........................3
第二章 鋸帶切削及量測基礎理論.............5
2.1 鋸帶之基本理論....................5
2.2 鋸帶之齒通頻率....................6
2.3 切削下壓力計算....................6
2.4 訊號處理方法......................9
2.5 取樣定理.........................9
2.4.1 快速傅立葉轉換....................9
2.4.2 均方根值.........................10
2.6 表面粗糙度.......................10
2.5.1 中心線平均粗糙度(Ra)..............10
2.5.2 最大粗糙度(Rmax)..................10
2.7 皮爾森相關係數....................11
第三章 實驗內容與方法......................12
3.1 實驗流程..........................12
3.2 實驗設備與切削材料介紹.............13
3.2.1 實驗機台..........................13
3.2.2 實驗儀器..........................14
3.2.3 切削材料與切削參數.................19
3.3 實驗訊號分析方法...................20
第四章 結果與討論..........................25
4.1 切削振動分析.......................26
4.1.1 不鏽鋼與中碳鋼切削振動趨勢分析.......26
4.1.2 不鏽鋼與中碳鋼切削振動差異...........27
4.2 切削負載分析........................30
4.2.1 不鏽鋼與中碳鋼切削負載趨勢分析........30
4.2.2 不鏽鋼與中碳鋼切削負載差異............31
4.3 鋸切歪斜分析........................34
4.3.1 不鏽鋼與中碳鋼鋸切歪斜趨勢分析........34
4.3.2 不鏽鋼與中碳鋼鋸切歪斜差異............35
4.4 表面粗糙度分析.......................38
4.4.1 不鏽鋼與中碳鋼表面粗糙度趨勢分析.......38
4.4.2 不鏽鋼與中碳鋼表面粗糙度差異...........41
4.5 關聯性比較............................42
4.5.1 不鏽鋼與中碳鋼關聯性趨勢分析...........42
4.5.2 不鏽鋼與中碳鋼關聯性綜合探討...........46
第五章 結論..................................48
第六章 未來展望..............................49
參考文獻.....................................50
Extended Abstract............................52

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