臺灣博碩士論文加值系統

CNC 的銑刀盤在銑削大面積與重切削時，易發生刀體與刀具溫度累積而造成
刀片耗損與崩壞，或排屑不良等現象。此現象將導致刀具振動增加，將造成切削
效率產生變異，從而產生面粗度劣化與刀具可用壽命縮短等問題。因此，如何有
效降低刀具加工時所產生的溫度累積，並能同時提升排屑效率，實為開發銑刀盤
實務挑戰。
本研究利用雷射粉床式融合(Laser Powder Bed Fusion)的積層製造方法，以開
發一具異形流道及噴嘴之銑刀盤。在製造機台與材料上，藉由設計一製程極限基
準件，可根據國產積層製造設備與金屬粉末特性，評估在製造不同幾何圖形與微
小特徵時，所能獲得的最小尺寸極限。在設計方法上，藉由設計與測試不同孔徑
之內流道模型，與具噴嘴機構的出口端流道模型，可獲得在穩定進水量下最佳流
道及噴嘴尺寸，並導入於銑刀盤設計內。
研究結果顯示，在製造極限下據以製作出之銑刀盤 HRC 達 52，在轉速 3000
rpm 下動平衡等級可達 G2.5。此外，當異形流道孔徑為 ø3-ø3.5 mm 並搭配噴嘴
設計時，在具中心出水的 CNC 設備上，射流效果可提升 2.25 倍。因此，本研究
所開發的積層製造方法，除可善用國產設備與材料之外，製造出高於一般刀盤的
鋼性、動態特性，更能降低刀具溫度的積層製造銑刀盤，將可進而延長刀具壽命
及提升加工品質。

When milling large areas and heavy cutting, a CNC milling cutter could occur the
tool wear and break causing from temperature accumulation, as well as pool chip
removal. That may increase tool vibration and induce variation in cutting efficiency, so
as cause deteriorating the workpiece surface roughness and shortening of the tool useful
life. Therefore, how to effectively reduce the temperature accumulation generated
during processing and improve the chip removal efficiency at the same time is a
practical challenge for development of a milling cutter.
In this study, a laser powder bed fusion based manufacturing method is proposed to
develop a milling cutter with a conformal cooling channel and nozzle. For the
manufacturing machine and materials, a benchmarking is designed according to the
characteristics of domestic additive manufacturing machine and metal powder. A
workpiece can be manufactured to meet the hardness and dimensional tolerances under
the limits of geometric features. In the design method, the optimal flow channel and
nozzle size under a stable water intake can be obtained and introduced into the milling
cutter design based on the testing results of various flow channels with different
apertures and nozzles.
The research results show that the produced milling cutter under manufacturing limit
can reach the HRC of 52 and the dynamic balance level of G2.5 at 3000 rpm. When
equipped with the diameter of the conformal cooling channel ø3-ø3.5 mm with the
nozzle, the jet effect can be increased by 2.25 times on the CNC equipment with central
water discharge. Therefore, in addition to utilizing domestic equipment and materials,
the proposed additive manufacturing method can produce a layered manufacturing
milling cutter with higher hardness, balance, and cooling characteristics, furthermore,
the tool life and workpiece quality can be enhanced.

目錄
摘要 i
Abstract ii
誌謝 iii
目錄 iv
表目錄 vi
圖目錄 vii
符號說明 x
第1章 緒論 1
1.1 研究背景 1
1.2 研究動機與目的 5
1.3 本文架構 7
第2章 積層製造技術相關文獻探討 8
2.1 L-PFB(Laser Powder Bed Fusion)介紹 8
2.2 積層製造基準(Additive Manufacturing Benchmarking) 9
2.2.1 多款基準件設計規範 9
2.2.2 基準件設計規則指南 16
2.3 內流道及噴嘴結構 18
2.3.1噴嘴結構 18
2.4 金屬粉末特性 23
2.4.1 材料特性及應用 23
2.4.2 機械特性 25
第3章 金屬積層製造銑刀盤之分析與設計 26
3.1 分析流程 26
3.2 分析設備與材料 27
3.3實驗步驟 27
3.3.1 製程參數搜尋 28
3.3.2 基準件設計實驗 33
3.3.3內流道設計實驗 35
3.3.4 噴嘴設計實驗 37
3.3.5 銑刀盤設計實驗 39
第4章 積層製造銑刀盤之開發與測試 41
4.1參數搜尋結果分析 41
4.2基準件設計結果分析 46
4.2.1 製程能力檢測 46
4.2.2 精度量測 48
4.3 內流道設計結果分析 51
4.4 噴嘴設計結果分析 54
4.5 銑刀盤設計結果分析 56
第5章 結論與未來展望 59
5.1 結論 59
5.2未來研究方向 60
參考文獻 61
附錄一 65
附錄二 66
附錄三 67
附錄四 68
附錄五 69
附錄六 70
附錄七 71

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