臺灣博碩士論文加值系統

刀具產業中各家刀具廠在設計刀具幾何角度方面都有各自的「know-how」，然而在設計刀具幾何角度時，通常會依據不同材料的機械性質及切削時的切削參數不同而有所不同。其中刀具幾何角度主要包含楔型角、切削角、離隙角與螺旋角；機械性質主要包含降伏強度、抗拉強度、楊氏係數、硬度、剪切強度、導熱係數、韌性；切削參數主要包含主軸轉速、進給率、每刃進給、徑向切深、軸向切深。隨著材料的硬度與強度以及切削參數的值增加而改變楔型角的角度大小，才有足夠的強度抵抗切削時的所產生的反作用力；法向離隙角的設計與材料的楊氏係數及韌性有關，主要避免切削過程中新生成的材料表面產生回彈進而導致刀腹面被彈破的現象。
在國外對於刀刃口微幾何研究已經有一段時間，但台灣對這部分的研究與國外還是有相當的落差，透過刀刃口微幾何的技術能大幅提升刀具壽命與刀刃口的穩定度，避免過早出現刃口崩損的現象，這部分就涉及了各刀具製造商的商業機密，可查詢的技術資料相當有限。因此，本論文使用3種代表性合金鋼(淬火SKD61、NAK80與SCM440)的機械性質以設計刀具的楔型角、切削角及法向離隙角，尋找切削合金鋼時統一的刀具幾何角度，在固定刀具幾何角度與切削距離條件下，可以找出對於不同的材料與不同切削參數所適合的刀刃口微幾何。

In the cutting tool industry, each cutting tool factory has its own "know-how" in designing the geometric angle of the cutting tool. However, when designing the geometric angle of the cutting tool, it usually varies according to the mechanical properties of different materials and the cutting parameters during machining. Among them, the geometric angle of the tool mainly includes wedge angle, rake angle, relief angle, and helix angle. The mechanical properties mainly include yield strength, tensile strength, Young's modulus, hardness, shear strength, thermal conductivity, and toughness. The cutting parameters mainly include spindle speed, feed rate, feed per tooth, radial depth of cut, axial depth of cut. As the hardness and strength of the material and the value of the cutting parameters increase, the wedge angle of cutting tools is changed to have sufficient strength to resist the reaction force generated during cutting. The design of the normal relief angle is related to the Young's modulus of the material and the toughness to avoid the springback of the surface of the newly generated material during the cutting process which will lead to the phenomenon that the flank surface of the tool is broken.
There has been research on the micro geometry of the cutting edge abroad for a while, but the research time of this part in Taiwan is still compared with that of foreign countries. There is a considerable gap. The reason is that through the micro geometry technology of the cutting edge, the tool life and the stability of the cutting edge can be greatly improved, and the broken phenomenon of cutting edge can be avoided. This part involves the commercial secrets of various cutting tool manufacturers. Thus, the available technical information is quite limited. Therefore, this thesis uses the mechanical properties of three representative alloy steels (quenched SKD61, NAK80, and SCM440) to design the wedge angle, rake angle, and normal relief angle of the tool to find a unified geometric angle of the tool when cutting alloy steels. Under the conditions of fixed tool geometric angles and cutting length, this study can find out the suitable micro geometry of cutting edge for cutting different materials under different cutting parameters.

摘要...i
ABSTRACT...ii
誌謝...iv
目錄...v
表目錄...viii
圖目錄...x
符號說明...xiii
第一章 緒論 1
1.1 研究背景 1
1.2 研究動機與目的 1
1.3 文獻回顧 2
1.4 研究流程 3
1.5 論文架構 3
第二章 基礎理論 5
2.1 端銑刀具 5
2.1.1 端銑刀刃數 5
2.1.2 端銑刀具刃口與旋向 5
2.1.3 端銑刀具幾何角度 6
2.1.4 徑向切削角 7
2.1.5 軸向切削角 8
2.1.6 徑向離隙角 9
2.1.7 軸向離隙角 12
2.1.8 螺旋角 12
2.1.9 楔型角 13
2.2 微幾何量測 13
2.2.1 刀刃口微幾何-圓角量測 13
2.3 切削理論 18
2.3.1 切削模型 18
2.3.2 銑削加工型式 21
2.3.3 順銑法(climb milling) 21
2.3.4 逆銑法(conventional milling) 21
2.3.5 切削參數 22
2.3.6 切削力 22
2.3.7 切線速度 22
2.3.8 每刃進給 22
2.3.9 徑向切深與軸向切深 23
2.4 刀具磨耗 23
第三章 實驗設備 25
3.1 TOOL STUDIO刀具研磨軟體 25
3.2 TD-5砂輪修整機 26
3.3 HELITRONIC BASIC刀具研磨機 27
3.4 KEEJAAN KJ-202 刀具量測儀 28
3.5 ZOLLER GENIUS3S刀具量測儀 28
3.6 TAKUMI B8三軸工具機 29
3.7 OLYMPUS STM 6高精度工具顯微鏡 30
3.8 EDSING POLL TECH PT-G4鈍化機 31
3.9 ZOLLER POMSKPGO鈍化儀 32
3.10 ABDUCTORY INDUCTION MECHANISM (AIM)軟體 33
第四章 實驗設計與規劃 34
4.1 .前測試 34
4.1.1 合金鋼楔型角 34
4.1.2 加工測試參數 34
4.2 刀具鈍化 35
4.3 刀具磨耗量測方法 39
4.4 前測試實驗結果 40
4.4.1 刀具幾何角度 40
4.4.2 切削參數結果 40
4.5 主要實驗設計 41
第五章 實驗結果與討論 42
5.1 淬火SKD61刀腹磨耗量測結果 42
5.2 NAK80刀腹磨耗量測結果 49
5.3 SCM440刀腹磨耗量測結果 56
5.4 不同半徑大小切削合金鋼的比較 62
5.5 縮小鈍化範圍的比較 62
5.5.1 縮小鈍化值範圍對切削淬火SKD61之刀腹磨耗影響 62
5.5.2 縮小鈍化值範圍對切削NAK80之刀腹磨耗影響 68
5.5.3 縮小鈍化值範圍對切削SCM440之刀腹磨耗影響 70
第六章 結論與未來展望 75
6.1 結論 75
6.2 未來展望 75
參考文獻 76
EXTENDED ABSTRACT 78
ABSTRACT 78
1. INTRODUCTION 80
2. EFFECTS OF PASSIVATION PROCESS TIME 80
3. EXPERIMENTAL RESULTS 82
4. CONCLUSIONS 83

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