臺灣博碩士論文加值系統

鏟花是提升工具機性能的重要手段，然而鏟花加工是每間公司的技術秘密，是老師傅多年工作經驗與智慧結晶的累積，因此至今沒有量化的最佳鏟花界面準則可以遵循及可靠的壽命預測方法，以致在鏟花自動化的發展上缺少了最佳加工表面的特徵標準與維修指標。本論文利用自製測試機器對商業用的鏟花耐磨片進行長時間實驗，通過分析鏟花耐磨片的表面特徵變化、油中磨屑顆粒數量與大小變化、耗能變化，並搭配三體微接觸理論的互相驗證，發現:(1)鏟花耐磨片的界面固體負荷百分比(LS)及實際量測的表面溫度上升可以證明鏟花界面運轉於史崔派克曲線圖的最低摩擦係數區。(2)對照塑性指數(ψ)可以發現鏟花耐磨片運行在輕微的混合潤滑區域，且是以塑性變形為主的彈性與塑性變形混合接觸型態，並非一般所指的彈液動潤滑。(3)從斜度值(Ssk)及高原面積百分比(POP)可以知道鏟花耐磨片的表面是有著二層次的油袋含油流動，讓潤滑油容易進入表面進行潤滑，以上這三點就是鏟花能實現低摩擦和穩定運行的主要原因與機理。(4)從表面形貌中的 POP、每平方英寸的高原數(PPI)、平均粗度值(Sa)、均方根粗度值(Sq)、Ssk、旋度值(Sku)、波峰密度(η)、波峰曲率半徑(Rp)，發現實驗後的 POP、Sa、Sq、Sku等數值在最後階段有往上升趨勢，此時表明鏟花耐磨片的性能在逐漸劣化。(5)鏟花面運轉初期以拋光磨耗為主，以致 Sq 與 η 值均下降，Rp 值急速增加，中期為拋光磨耗與砂磨磨耗混合，η 值上升 Sq 值穩定，後期劣化過程則以砂磨磨耗為主，Sq 逐漸上升 η 值穩定。(6)由鏟花片與磨屑成分分析，及銅顆粒的表面砂磨痕跡顯示，鏟花片運轉初期的磨屑顆粒來自鏟花耐磨片內銅顆粒，中期以後的磨屑顆粒是銅顆粒與碳鋼滑塊兩種材料組合。(7)經過理論與實驗結果綜整，建議以 Sq、Ssk與 POP 三項參數，配合影像系統，作為鏟花片劣化嚴重性的準則與修復的指標。(8)以三體微接觸理論公式為基礎，代入鏟花材料、磨屑顆粒大小與濃度、表面粗度參數、機台速度與負荷，配合史崔拜克圖的量化曲線，即可選擇適當 POP 與PPI，控制鏟花片運轉於最佳低摩擦區運轉條件。並可依 POP、Sq、Ssk 的變化進行維修。

The process of hand scraping is a critical technique for enhancing machine tool performance. However, hand scraping methods are often proprietary secrets held by companies, built on the extensive experience and wisdom of skilled craftsmen accumulated over many years. As a result, there is currently no standardized quantitative guideline for optimal scraped interfaces or a reliable method for lifespan prediction. This lack of standardization has hindered the development of automation in hand scraping, especially in establishing criteria for optimal surface characteristics and maintenance indicators. This study utilizes a self-designed testing machine to conduct long-term experiments on commercially available wear-resistant scraped plates. By analyzing changes in the surface characteristics of the scraped plates, variations in the number and size of wear particles in the oil, energy consumption, and verifying these with three-body micro-contact theory, the following findings are observed: (1) The solid load percentage (LS) at the scraped interface and the actual measured surface temperature rise confirm that the scraped interface operates in the region of the Stribeck curve with the lowest coefficient of friction. (2) The comparison of the plasticity index (ψ) reveals that the scraped wear-resistant plate operates in a mild mixed lubrication region, characterized by a contact pattern dominated by plastic deformation in a mix of elastic and plastic deformation, rather than the typically mentioned elastohydrodynamic lubrication. (3) The skewness (Ssk) and Percentage of Point (POP) indicate that the surface of the scraped plate features a two-tiered oil pocket structure, which facilitates the entry of lubricating oil, contributing to effective lubrication. These three factors are the primary reasons and mechanisms behind the low friction and stable operation achieved by scraping. (4) Analysis of the surface topography, including parameters such as POP, Point Per Inch (PPI), average roughness (Sa), root mean square roughness (Sq), Ssk, kurtosis (Sku), peak density (η), and peak curvature radius (Rp), shows that values such as POP, Sa, Sq, and Sku exhibit an upward trend in the final phase, indicating the gradual degradation of the scraped wear-resistant plate’s performance. (5) During the initial operation phase, polishing wear dominates, leading to a decrease in Sq and η values and a rapid increase in Rp. In the mid-phase, a combination of polishing and abrasive wear occurs, with η increasing and Sq stabilizing. In the final degradation phase, abrasive wear predominates, with Sq rising and η stabilizing. (6) Analysis of the composition of the scraped plate and wear particles, as well as the abrasion marks on copper particles, shows that in the initial operation phase, the wear particles primarily come from the copper particles in the scraped wear-resistant plate, while in the later stages, the particles are a mix of copper and carbon steel slider materials. (7) Based on the theoretical and experimental results, it is recommended that Sq, Ssk, and POP parameters, along with an imaging system, be used as criteria for evaluating the severity of degradation and indicators for restoring the scraped plate. (8) By applying the three-body micro-contact theory and incorporating variables such as the scraped material, wear particle size and concentration, surface roughness parameters, machine speed, and load into the Stribeck curve, one can select appropriate POP and PPI values to control the scraped plate’s operation within optimal low-friction conditions. Maintenance can be performed based on the changes in POP, Sq, and Ssk.

摘要...........................................................................................i
Abstract....................................................................................iii
誌謝..........................................................................................v
目錄.........................................................................................vi
表目錄....................................................................................viii
圖目錄......................................................................................ix
符號說明.................................................................................xiii
第一章、緒論............................................................................1
1.1前言......................................................................................1
1.2研究目的..............................................................................3
1.3文獻回顧..............................................................................4
1.3.1鏟花表面分析文獻.............................................................4
1.3.2自動鏟花文獻....................................................................6
1.4論文架構..............................................................................6
第二章、理論分析.....................................................................8
2.1界面接觸型態.......................................................................8
2.1.1均方根粗度值(Sq).............................................................8
2.1.2斜度(Ssk)..........................................................................8
2.1.3塑性指數(ψ)......................................................................9
2.2潤滑境域..............................................................................9
2.3三體界面負荷關係..............................................................10
2.4三體接觸溫度模式..............................................................12
第三章、實驗方法與儀器........................................................15
3.1鏟花磨耗實驗規劃..............................................................16
3.2滑動導軌鏟花面磨耗試驗機................................................17
3.2.1滑動導軌鏟花面磨耗試驗機實驗步驟..............................19
3.2.2滑動導軌鏟花面磨耗試驗機注意事項..............................19
3.3非接觸熱像儀量測..............................................................19
3.3.1非接觸熱像儀實驗步驟....................................................20
3.3.2非接觸熱像儀注意事項....................................................21
3.4智慧電量監控.....................................................................21
3.4.1智慧電量監控(KM50-E)實驗步驟....................................21
3.4.2智慧電量監控(KM50-E)注意事項....................................22
3.5三維光學粗度儀.................................................................22
3.5.1三維光學粗度儀實驗步驟................................................22
3.5.2三維光學粗度儀注意事項................................................23
3.6奈米粒徑分析儀.................................................................23
3.6.1奈米粒徑分析儀實驗步驟................................................23
3.6.2奈米粒徑分析儀注意事項................................................24
3.7光學顯微鏡.........................................................................24
3.7.1光學顯微鏡實驗步驟........................................................25
3.7.2光學顯微鏡注意事項.......................................................25
3.8分析型場發掃描式電子顯微鏡( SEM / EDS ).....................25
3.8.1分析型長發掃描式電子顯微鏡實驗步驟..........................26
3.8.2分析型長發掃描式電子顯微鏡注意事項..........................27
第四章、結果與討論...............................................................28
4.1表面形貌分析.....................................................................28
4.1.1高原面積百分比(POP)與每平方英吋的高原數(PPI)........29
4.1.2平均粗度值(Sa)...............................................................30
4.1.3均方根粗度值(Sq)...........................................................32
4.1.4斜度(Ssk)........................................................................35
4.1.6油袋平均深度(Dmean)....................................................37
4.1.7波峰密度(η).....................................................................39
4.1.8波峰曲率半徑(Rp)...........................................................41
4.1.9塑性指數(ψ).....................................................................42
4.2滑軌油顆粒分析..................................................................43
4.2.1平均顆粒大小與顆粒濃度.................................................43
4.3.1鏟花面成分分析...............................................................45
4.3.2滑軌油中顆粒成分分析....................................................52
4.4滑軌溫度分析.....................................................................55
4.5摩擦力分析.........................................................................57
4.6三體接觸模式分析..............................................................58
4.6.1無因次化真實接觸面積....................................................58
4.6.2固體負荷百分比...............................................................59
4.6.3平均表面接觸溫升...........................................................60
4.7馬達耗電量分析..................................................................61
4.7.1馬達功率..........................................................................62
4.7.2馬達電流..........................................................................63
4.8不同POP鏟花片對鏟花界面特性.........................................65
第五章、結論與未來展望.........................................................72
5.1結論.....................................................................................72
5.2未來展望..............................................................................74
參考文獻...................................................................................75
EXTENDED ABSTRACT..........................................................77

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