臺灣博碩士論文加值系統

隨著工具機高速化與高精度化的性能要求，其結構設計必須有足夠的剛性，以有限元素分析為基礎進行工具機虛擬製造分析研究，在電腦上實現從工具機構想、設計、加工等，可提前預估機械的性能，並降低設計變更與加工錯誤的風險。本研究主要是在以往累積之工具機技術發展的基礎上，進行機台之設計分析與性能研究，並從理論分析、時變結構負載與實驗探討工具機精度與結構之改善設計。
本研究首先探討工具機結構的強度，將工具機的主結構進行有限元素分析，分析靜剛性、模態、頻譜與暫態響應分析等，將工具機主結構進行靜剛性、模態、頻譜與暫態響應分析等，根據工具機實際的條件與物理現象，去設定並建立完整的分析模型，使分析結果更加符合實際的機台特性，並搭配儀器去做實驗以驗證分析結果，進行模態測試之敲擊實驗，運用加速規擷取激振後的訊號，將訊號匯入模型中，把結構的自然頻率及振型的可視化，可以比對模擬的分析結果與實際結構的自然頻率及振型，進一步比對，了解分析模型與實際模型之間的差異，同時考量機台運動之結構負載、靜動態實驗結果與組合介面參數比對，進一步分析數值的正確性。此外實驗研究過程中會運用感測器收集工具機加工時的振動數據，透過資料處理與分析，將機台訊號傳換為資訊，進行加工狀態預測，建構機台健康狀態監控的技術，並將相關診斷技術運用於實際切削加工應用，進一步提升工具機智慧化的能力。

High-speed and high-precision machine tools must possess an optimal design structure and high rigidity. The virtual model analysis and research of machine tools are possible on a computer using the finite element analysis to predict the machine performance in advance and reduce the risk of design changes and processing errors by considering factors such as the tool mechanism thinking, design, processing, etc. In this study, we carried out the design analysis and performance research of the machine, based on the machine tool technology developments from the past, to explore the optimal design for machine tool accuracy and structure from theoretical analysis, time-varying structural load, and experiments.
First, we carried out the finite element analysis of the main structure of the machine tool to explore its strength and analyze factors such as static rigidity, modal, frequency spectrum, and transient response analysis by considering the time-varying structural load and static and dynamic machine movements. Based on the actual conditions and the physical phenomena of the machine tool, we established an analysis model, corresponded the analysis results to the actual machine characteristics, and performed experiments to verify the analysis results. Furthermore, we performed the percussion experiment of the modal test using an accelerometer to capture the excited signal and import it into the model. We compared the actual and simulated analysis results of the natural frequency and mode shape of the structure to analyze the difference between the analysis model and the actual model. To further verify the differences between the analytical model and the actual model, a static rigidity experiment was conducted to measure the force and deformation using the force sensor and displacement measurement and compared the results with the combined interface parameters to analyze the correctness of the values. Moreover, sensors were used in the experimental research to collect the vibration data signal during machining of the tool, which was converted to information through data processing and analysis to predict the machining and develop a machine health monitoring technology. Furthermore, we used relevant diagnostic technology for actual cutting processing applications to further enhance the intelligence-based capabilities of machine tools.

摘要.............................................................i
Abstract......................................................ii
誌謝............................................................iii
目錄............................................................iv
表目錄........................................................vii
圖目錄.......................................................viii
符號說明.....................................................xii
第一章 緒論..................................................1
1.1 研究背景................................................1
1.2 研究目的................................................1
1.3 文獻探討................................................2
1.4 論文大綱................................................3
第二章 基礎理論與實驗設備.........................5
2.1 有限元素法概述......................................5
2.1.1 有限元素概念.......................................6
2.1.2 有限元素種類.......................................6
2.1.3 有限元素法公式法................................7
2.2 振動與模態基礎理論..............................10
2.2.1 單自由度系統.....................................10
2.2.2 實驗模態分析簡介..............................12
2.3 靜剛性基礎理論.....................................12
2.4 實驗設備................................................13
2.4.1 三軸工具機QP1620-L.........................13
2.4.2 力量感測器與顯示器...........................14
2.4.3 施力進給機構......................................16
2.4.4 位移計.................................................16
2.4.5 固定治具與磁性座錶架........................18
2.4.6 衝擊槌.................................................19
2.4.7 加速規.................................................20
2.4.8 頻譜分析儀..........................................21
2.4.9 有限元素分析軟體ANSYS...................22
2.4.10 模態分析軟體ME’scope.....................23
2.4.11 高精度工具顯微鏡Olympus STM 6...........23
2.4.12 表面粗糙度量測儀Surfcorder SE-700.......24
第三章 有限元素分析與模型驗證..................25
3.1 有限元素分析..........................................25
3.1.1 前處理..................................................25
3.1.2 模型簡化..............................................26
3.1.3 材料性質..............................................27
3.1.1 網格收斂性分析...................................27
3.1.2 網格品質..............................................28
3.1.3 邊界條件..............................................28
3.1.4 檢查模型介面.......................................30
3.2 求解運算.................................................30
3.3 後處理.....................................................31
3.3.1 靜態分析..............................................31
3.3.2 模態分析...............................................38
3.3.4 暫態分析...............................................39
3.4 模型驗證...................................................40
3.4.1 靜剛性實驗............................................40
3.4.2 主軸靜剛性測試.....................................41
3.4.3 整機靜剛性測試.....................................42
3.4.4 靜剛性實驗與靜態分析結果對比............43
3.4.5 模態實驗................................................44
3.4.6 敲擊實驗量測點配置..............................44
3.4.7 敲擊實驗.................................................47
3.4.8 模態參數-曲線擬合.................................51
3.4.9 模態實驗與模態分析結果對比................54
3.4.10 模態實驗與暫態分析結果對比..............56
第四章 拓樸最佳化..........................................57
4.1 結構最佳化設計.........................................57
4.1.1 拓譜最佳化方案......................................58
4.1.1 結構改良設計.........................................58
4.1.2 拓譜最佳化設定......................................59
4.1.3 拓譜最佳化分析結果...............................63
4.1.4 改良結構與原結構比較............................64
第五章 智慧化加工研究....................................71
5.1 切削實驗.....................................................71
5.1.1 切削刀具..................................................71
5.1.2 實驗參數..................................................72
5.2 量測方法.....................................................74
5.2.1 表面粗糙度與表面刀紋............................74
5.2.2 切削時主軸之振動量之量測.....................77
5.2.3 實驗結果對比...........................................78
5.3 切削訊號分析..............................................87
5.3.1 訊號分析..................................................87
5.3.2 特徵萃取..................................................87
5.3.3 主成分分析法...........................................88
5.3.4 自組織映射..............................................89
第六章 結論與未來展望....................................91
6.1 結論............................................................91
6.2 未來展望.....................................................92
參考文獻...........................................................93
Extended Abstract............................................95
Abstract............................................................95
1.Introduction....................................................96
2.Finite Element Analysis and Experiment.......96
3.Topology Optimization Design.......................98
4.Intelligent processing.....................................98
5.Discussions and Conclusion..........................99
Reference........................................................101
簡歷(CV)..........................................................102

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