臺灣博碩士論文加值系統

本研究針對平面磨床進行模態分析、結構剛性鑑別以及各種輔助磨削實驗，以提升磨削之表面精度品質。首先，分別對部件與機台進行數值模態分析與實驗模態分析，並以實驗模態分析為目標基準，對數值模態分析結果中的部件模型進行簡化與收斂性分析。接著，再應用材料力學公式計算出各介面剛性初估值，針對影響模態參數最為顯著的地腳剛性以試誤法進行剛性初估值調整，促使數值模態分析與實驗模態分析之自然頻率誤差趨於 ± 5%範圍內。
本次實驗選用耐磨耗且導熱係數較佳之鑽石砂輪對氧化鋯進行超音波輔助、雷射預熱輔助以及混合輔助磨削實驗並於磨削過程中反覆調整製程參數。本實驗分為二個階段，第一階段基於相同材料移除率比較有無超音波輔助之結果，驗證本實驗之超音波輔助磨削是否具有效益。第二階段則使用磨削製程參數(主軸轉速、磨削深度、進給速度)的調變進行各種輔助磨削實驗，規劃建立直交表。於磨削實驗時使用動力計監測三軸向磨削力的變化、使用加速度規監測磨削區的振動以及分別使用表面粗糙儀與3D全角度光學顯微鏡量測與觀測加工完成面之表面粗糙度與缺陷。以加工完成之表面粗糙度為目標函數，同時受制於工件表面缺陷的拘束條件下，配合田口法的望小特性以檢視超音波輔助、雷射輔助以及混合輔助對氧化鋯之磨削性能並求得合乎業界加工品質要求之較佳製程參數。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與較小的磨削力，使用混合輔助之磨削性能更優於其他輔助。其中，混合輔助磨削相較於超音波輔助磨削最大可降低約25%的表面粗糙度與33%的磨削力。而混合輔助磨削相較於雷射輔助磨削最大則可以降低約28%的表面粗糙度與17%的磨削力。透過各種不同製程參數組合磨削性能的比對，驗證混合輔助為本文較佳的輔助系統，其較佳製程參數組合為高主軸轉速，低切削深度以及低進給率。

This study focuses on modal analysis, structural stiffness identification, and various assisted grinding experiments for a surface grinding machine to enhance the surface accuracy and quality of grinding. Firstly, numerical modal analysis and experimental modal analysis are conducted separately on the components and the whole machine. Using the results of experimental modal analysis as the reference benchmark, the component models from the numerical modal analysis results are simplified and convergence analysis is performed. Subsequently, mechanics of material formulas are applied to calculate the initial estimates of interface stiffness values. Trial-and-error adjustments are made to the initial stiffness estimates, particularly for the footing stiffness that significantly affects the modal parameters. The goal of this is to ensure that the discrepancy in natural frequencies between numerical modal analysis and experimental modal analysis is within ±5% range
In this experiment, wear-resistant and thermally conductive diamond grinding wheels were selected to perform ultrasonic-assisted, laser preheating-assisted, and hybrid-assisted grinding experiments on zirconia, with the process parameters adjusted iteratively during the grinding process. The experiment consists of two phases: in the first phase, the results with and without ultrasonic-assisted grinding were compared based on the same material removal rate to verify the effectiveness of the ultrasonic-assisted grinding. In the second phase, various assisted grinding experiments were conducted by varying grinding process parameters (spindle speed, grinding depth, feed rate), and an orthogonal array was designed. During the grinding experiments, dynamometer was used to monitor the changes in three-axis grinding forces, accelerometer was employed to monitor the vibration in the grinding zone, and a surface roughness instrument and a 3d digital microscope were used to measure the surface roughness and surface defect of the finished surface, respectively. With the finished surface roughness as the objective function and constrained by the surface defects on the finished surface, the Taguchi method was employed to examine the grinding performance of ultrasonic-assisted, laser-assisted, and hybrid-assisted grinding on zirconia and determine the optimal process parameter combinations that meet the industry's quality requirements. The results showed that compared to no assistance, ultrasonic-assisted grinding achieved better surface roughness and lower grinding forces. The grinding performance prevailed over other methods when using hybrid assistance. Specifically, the hybrid-assisted grinding reduced surface roughness by approximately 25% and grinding forces by 33% compared to ultrasonic-assisted grinding. Compared to laser-assisted grinding, hybrid-assisted grinding reduced surface roughness by about 28% and grinding forces by 17% at maximum. By comparing the grinding performance with various combinations of process parameters, the hybrid assistance system was validated as the preferable approach in this study, with the optimal process parameter combination being high spindle speed, low cutting depth, and low feed rate.

摘要......i
Abstract......ii
誌謝......iv
目錄......v
表目錄......vii
圖目錄......viii
第一章 緒論......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......7
第二章 理論基礎......9
2.1 頻率響應函數......9
2.2 磨削原理......12
2.3 超音波輔助加工原理......13
2.4 雷射輔助切削原理......13
2.5 田口實驗方法......14
第三章 模態分析與模型驗證......16
3.1 模態分析......16
3.2 單部件模態分析結果......23
3.3 磨床接觸介面剛性......32
第四章 結合超音波與雷射預熱磨削實驗......39
4.1 實驗流程......39
4.2 實驗儀器規格與材料特性......40
4.3 氧化鋯磨削實驗方法與執行步驟......49
第五章 結果與討論......52
5.1表面粗糙度......52
5.2磨削力......55
5.3磨削振動......5
5.4表面缺陷......61
第六章 結論......65
參考文獻......67
附錄A......69
附錄B......71
Extended Abstract......79

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