臺灣博碩士論文加值系統

藍寶石具有優越的光學、化學、機械及物理等相關等性質，亦即它具有高硬度、高聲速、高脆性、高強度、良好電絕緣體、低介電質損失、高折射率、抗腐蝕、耐高溫、高透光性、熔點高、耐磨耗、顏色豐富、透明度變化大等特點。目前工業主要應用為光學或電子元件基底材料、機械軸承零件及軍工材料等。
本文建構藍寶石不同輔助磨削階梯實驗並對A及C平面分別進行磨削性能探討期尋找出最佳輔助情況及製程參數。本實驗分為兩個部分，第一部分基於相同材料移除率（進給速率與徑向切深之適當組合）在三種超音波輔助（包含旋轉超音波、雙軸超音波及旋轉與雙軸超音波(三軸超音波)結合的小混合輔助）與無輔助情況下進行實驗，冀以求得較佳的超音波輔助情況。第二部份引用第一部份之最佳輔助情況，並透過田口法直交表加工製程參數（主軸轉速、進給速率、徑向切深）的調變規劃，同時導入雙軸雷射預熱輔助，期進一步改善藍寶石階梯磨削性能及求得最佳製程參數。本實驗採用鑽石磨棒的側刃與底刃同時分別針對藍寶石的A面及C面進行磨削，形成階梯磨削。使用動力計檢測切削力的變化，以工具顯微鏡觀測藍寶石階梯邊緣崩裂形貌及磨棒底刃磨耗，並以表面粗度儀進行表面粗糙度之量測等。最後，以加工完成之表面粗糙度為目標函數，同時受制於刀具壽命的拘束條件，配合田口品質法的望小特性以求得最佳的製程參數。結果顯示，與無輔助相比，使用超音波輔助能夠獲得較良好的表面粗糙度及較小的邊緣崩裂型貌，且旋轉與雙軸超音波結合的小混合輔助優於其他輔助。三軸超音波小混合與雙軸雷射結合的大混合輔助在表面粗糙度及切削力有更良好的表現。整體切削力下降約15%，表面粗糙度品質於A面與C面分別提升約6%與8%。透過各種情況不同組合磨削性能的交叉比對可證實三軸超音波與雙軸雷射結合的大混合輔助為本文最佳輔助方式，其最佳製程參數之組合為高主軸轉速、低進給率及低切深。

Sapphire has superior properties of optical, chemical, mechanical and physical, that is, it has high hardness, high sound velocity, high brittleness, high strength, good electrical insulation, low dielectric loss, high refractivity, high corrosion resistance, high temperature resistance, high light transmittance, high melting point, high abrasion resistance, rich colors, large changes in transparency, etc. At present, its main industrial applications are optical or electronic component substrate materials, mechanical bearing parts and military materials.
This study constructs the grinding ladder experiments for sapphire under different assisted environments to investigate the grinding performance for the A and C lattice plane surfaces, and to find a better assisted manner and the best process parameters. This experiment is divided into two parts. The first part is based on the same material removal rate (the proper combination of feed rate and radial depth of cut) under three kinds of ultrasonic assistances and experiment without assistance in order to find a better ultrasonic assisted manner. These assistances include rotary ultrasonic, biaxial ultrasonic and small hybrid assisted systems (a combination of rotary and biaxial ultrasonic and so called triaxial ultrasonic). The second part applies the better assisted manner obtained from the first part, establishes the process parameter (spindle speed, feed rate, radial depth of cut) planning of the Taguchi orthogonal array and introduces the biaxial laser preheating system simultaneously to create a large hybrid assisted system. It is further to improve the performance for sapphire ladder grinding and to obtain the best process parameter combination expectedly. In the experiment, the side cutting-edge and bottom cutting-edge of a diamond electroplate burs were used to grind the A and C lattice plane surfaces of sapphire, respectively, at the same time to form a ladder grinding manner. Dynamometer was used to monitor the variation of cutting force. Burs wear on bottom cutting-edge and the edge-cracking morphology around the latter edges of the sapphire were measured by tool-microscope off-line. Surface roughness measurement through a contact probe instrument is also performed. Finally, the characteristics of the smaller-the-better in Taguchi method are applied to determine the optimal combination of process parameters for sapphire ladder grinding, in which the machined surface roughness and wear of burs cutting-edge are used as object function and subjecting constraint, respectively. The results show that the better surface roughness and smaller edge-cracking are obtained under ultrasonic assisted grinding as compared with no assistance. The small hybrid assisted system prevails over the other ultrasonic assisted situations on grinding performance. Furthermore, the large hybrid assisted system, a combination of small hybrid assisted system and biaxial laser preheating system, has a better performance on surface roughness and cutting force than those of small hybrid assisted system. Under this circumstance, the overall cutting force is reduced by about 15%, and the surface roughness quality is improved by about 6% and 8% on the A and C lattice plane surfaces, respectively, in this study. Through the cross-comparison of the grinding performance under different combinations of various situations in first and second part experiments, it can be confirmed that the large hybrid assisted system is the best assisted manner for sapphire ladder grinding in this study. The best process parameter combination obtained in this study is high spindle speed, low feed rate and low cutting depth.

中文摘要...i
Abstract...ii
誌謝...iv
目錄...v
表目錄...vi
圖目錄...vii
第一章 前言...1
1.1 研究背景...1
1.2 研究動機與目的...2
1.3 文獻回顧...3
1.4 論文架構...8
第二章 理論基礎...9
2.1 藍寶石材料特性...9
2.2 超音波輔助技術...9
2.3 雷射輔助切削技術...11
2.4 材料移除率...12
2.5 田口實驗方法...12
第三章 實驗方法與規劃...15
3.1 工件材料與刀具特性...16
3.2 實驗儀器設備與規格...17
3.3 實驗方法與執行步驟...31
第四章 結果與討論...35
4.1 表面粗糙度比較...35
4.2 切削力比較...41
4.3 藍寶石邊緣形貌比較...46
4.4 刀具磨耗比較...51
第五章 結論與建議...55
參考文獻...57
附錄...60
Extended Abstract...72

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