臺灣博碩士論文加值系統

本研究使用有限元素分析法為結構分析的工具，對立式磨床整機進行模態分析，根據實際現況條件與物理現象，設定與建立完整的分析條件，使結果更符合工具機的實際情況，並搭配相關儀器做實驗證明分析結果是否吻合，進行模態實驗的敲擊測試，先用衝擊槌敲擊引起的頻率響應，再運用加速規擷取激振的訊號，可以比對模擬分析與實際結構自然頻率與振型的差異。分析頻率範圍從1Hz~300Hz，主要的結構頻率分別為64.3Hz、93.4Hz與214.2Hz。分析結果可確認模態的頻率與振型的一致性。透過模態分析得知工具機結構中的弱點後，可進一步進行拓樸最佳化分析，並進行補強設計，提升立式磨床結構剛性。對立式磨床進行實際驗證，實驗設備是使用頻譜分析儀、加速規、衝擊槌搭配超軟橡膠錘頭，由衝擊錘敲擊主軸滑座上，使主結構產生激振，並再運用加速規擷取激振的訊號，頻譜分析儀搭配NOVIAN頻譜分析軟體對震動的訊號進行快速傅立葉轉換(FFT)把時域訊號轉換成頻域訊號，結果將顯示於頻譜分析之頻率響應函數、Time waveform、頻譜、關聯性等相關資訊，實驗結果:第一自然頻率:76.8Hz、第二自然頻率:87.0Hz、第三自然頻率:248.0Hz，擺動的方向與動作皆相同，可確認模型相關邊界條件設定的可信度與準確度，也可驗證分析模型與邊界條件是符合立式磨床實際的條件與物理現象。

In this study, we employed finite element analysis (FEA) to conduct modal research on an vertical grinding machine's structural characteristics. The objective of the investigation is to align analysis conditions closely with real-world conditions and physical phenomena. To validate our results, we conducted experiments using specific instruments, including a percussion hammer and an acceleration gauge. By comparing the natural frequencies and mode shapes obtained through simulation with those from physical testing, we ensured consistency in our findings. Our analysis covered a frequency range of 1Hz to 300Hz, highlighting key structural frequencies at 64.3Hz, 93.4Hz, and 214.2Hz. Subsequent to identifying structural weaknesses through modal analysis, it is planned to conduct topological optimization and reinforcement design to improve the machine's rigidity. Experimental verification of the vertical grinding machine involved the use of a spectrum analyzer, an acceleration gauge, and an impact hammer with an ultra-soft rubber tip. The impact hammer generated excitation in the main structure, while the acceleration gauge captured the response. We employed a spectrum analyzer in conjunction with NOVIAN spectrum analysis software to perform fast Fourier transforms (FFT) on vibration signals, converting them from the time domain to the frequency domain. The results provided detailed insights into frequency response functions, time waveforms, spectra, correlations, and other relevant data. Our experimental results revealed the machine's natural frequencies: 76.8Hz (first), 87.0Hz (second), and 248.0Hz (third). These results confirmed the reliability and accuracy of our model's boundary conditions, verifying their alignment with real-world conditions and physical phenomena of the vertical grinding machine.

摘要...i
Abstract...ii
誌謝...iii
目錄...iv
表目錄...ix
圖目錄...x
符號說明 ...xiv
第一章　緒論...1
1.1研究背景 ...1
1.2研究目的 ...1
1.3文獻回顧...2
1.4論文大綱...4
第二章 基礎理論與實驗設備...6
2.1 有限元素法原理...6
2.1.1有限元素法重要名詞...7
2.1.2有限元素類型...8
2.1.3有限元素法之平衡方程式...9
2.2模態與振動基礎理論...11
2.2.1單自由度系統...11
2.2.2模態測試簡介...12
2.2.3模態分析重要名詞...13
2.3主成分分析法...15
2.4實驗設備...16
2.4.1立式磨床EVU-818CNC...16
2.4.2有限元素分析軟體Ansys...18
2.4.3衝擊錘...19
2.4.4頻譜分析儀...20
2.4.5加速規...21
2.4.6模態分析軟體ME’scope...23
2.4.7智慧預測診斷系統(PDPS)...24
第三章　有限元素分析...26
3.1 有限元素分析...26
3.1.1建立有限元素模型...26
3.1.2 材料性質...27
3.2網格設置...28
3.2.1網格收斂性...29
3.3模型邊界條件設定...29
3.4.靜、動態特性分析...30
3.4.1靜剛性分析...30
3.4.2模態分析...31
3.4.3頻譜分析(Harmonic)...32
3.4.4暫態分析...34
3.5結構拓樸最佳化...35
3.5.1結構設計優化...35
3.5.2分析條件設定...36
3.5.3拓樸最佳化分析結果比較表...38
3.5.4整機拓樸最佳化結果比對...42
第四章　實驗測試與驗證...45
4.1模態實驗...45
4.1.1敲擊位置規劃...45
4.1.2敲擊實驗...48
4.2 Novian參數設定...49
4.3自然頻率分析...52
4.4模態分析與實驗驗證...54
4.5操作變形振型(ODS)...56
4.5.1敲擊位置規劃...56
4.5.2實驗結果驗證...58
第五章　智慧預測診斷...60
5.1主成分分析法簡介...61
5.2實驗設備介紹...62
5.3實驗規劃...63
5.4特徵萃取...63
5.5主成分分析法(PCA)...65
第六章　結論與未來展望...67
6.1結論...67
6.2未來展望...68
參考文獻 ...69
Extended Abstract...71
Abstract...71
1.Introduction...72
2.Finite Element Analysis and Experiment...72
3.Topology Optimization Design...75
4. Vertical Grinding Machine PDPS...77
5. Conclusion...79
Reference...80

[1]Pham, M.-N., Champliaud, H., Liu, Z., & Bonev, I. A. (2022). “Parameterized finite element modeling and experimental modal testing for vibration analysis of an industrial hexapod for machining.” Mechanism and Machine Theory, 167, 104502.
[2]R. Whalley, A. A. Abdul Ameer, K M Ebrahimi, 2011, “The axes response and resonance identification for a machine tool,” Mechanism and Machine Theory, Vol. 46, pp. 1171-1192.
[3]Yüksel, E., Budak, E., & Ertürk, A. S.(2017). “The effect of linear guide representation for topology optimization of a five-axis milling machine.” Procedia CIRP, 58, 487–492.
[4]Bilgili, D., Budak, E., & Altintas, Y. (2022). “Multibody dynamic modeling of five-axis machine tools with improved efficiency.” Mechanical Systems and Signal Processing, 171, 108945.
[5]Shi, H., Li, Y., Bai, X., Zhang, K., & Sun, X. (2022). “A two-stage sound-vibration signal fusion method for weak fault detection in rolling bearing systems.” Mechanical Systems and Signal Processing, 172, 109012.
[6]Florussen, G. H. J., Spaan, H. A. M., & Spaan-Burke, T. M. (2016). “Assessing the accuracy of five axis machines by comparing machine measurement data with test work piece deviations.” Procedia Manufacturing, 6, 25–32.
[7]Brandon C Gegg, Steve Suh, Albert C.J. Luo, 2010, “Modeling and theory of intermittent motions in a machine tool with a friction boundary,” Journal of Manufacturing Science and Engineering, Transactions of the ASME, Vol. 132, pp. 0410011-0410019.
[8]Mohammad Faraji Ghanati, Reza Madoliat, 2012, “New continuous dynamic coupling for three component modeling of tool-holder-spindle structure of machine tools with modified effected tool damping,” Journal of Manufacturing Science and Engineering, Transactions of the ASME, Vol. 134, pp. 0210151-0210170.
[9]Mahdi Eynian,2019, “In-process identification of modal parameters using dimensionless relationships in milling chatter,” International Journal of Machine Tools and Manufacture, Volume 143, Pages 49-62.
[10]Haibo Liu, Jiakun Wu, Kuo Liu, Kang Kuang, Qi Luo, Zhisong Liu, Yongqing Wang,2019, “Pretightening sequence planning of anchor bolts based on structure uniform deformation for large CNC machine tools,”International Journal of Machine Tools and Manufacture,Volume 136, Pages 1-18.
[11]Zengya Zhao , Sibao Wang , Zehua Wang , Ning Liu , Shilong Wang , Chi Ma , Bo Yang ,2020, “Interference- and chatter-free cutter posture optimization towards minimal surface roughness in five-axis machining,” International Journal of Mechanical Sciences,Volume 171, 105395.
[12]Hermans, L., and H. V. Auweraer, 1999, "Modal Testing andAnalysis of Structures Under Operational Conditions: Industrial Applications," Journal of Mechanical Systems and SignalProcessing, 193-216.
[13]Pilkey, W. D., and Chang, P. Y. 1978, Modern Formulas forStatics and Dynamics, McGraw-Hill International BookCompany.
[14]Nakada , T.. H. Tonosaki, and H. Yamashita, 1996, "Excitation Mechanism for Engine Vibration of Half-Order Components, "JSAE Review, pp. 387-393.
[15]Doebling, S. W., C. R. Farrar, M. B. Prime, and D. W. Shevitz,1996, "Damage Identification and Health Monitoring ofStructural and Mechanical Systems from Changes in theirVibration Characteristics: A Literature Review," Los AlamosNational Laboratory Report LA-13070-MS.
[16]N. Muthukrishnan, J. Paulo Davim,2009, “Optimization of machining parameters of Al/SiC-MMC with ANOVA and ANN analysis,” journal of materials processing technology, Volume 209, Page 225–232.
[17]Qianqian Ji, Congbo Li, Daoguang Zhu, Yan Jin, Yan Lv, Jixiang He, 2019, “Structural design optimization of moving component in CNC machine tool for energy saving,”Journal of Cleaner Production , 118976.
[18]Sitendra Nagesha, Mohit Law, 2019, “Machine tool design with preferentially asymmetrical structures to improve dynamics and productivity,” Procedia CIRP,Vol. 79, pp. 592–595.
[19]Tzu-Chi Chan, Yu-Ping Hong, Yu-Chuan Wang and Shang-Hung Wu, 2019“ Optimization Design of the Composite Structure of Linear Motor Machine Tools“, Journal of Mechanics Engineering and Automation 9 219-224.
[20]王柏村，實驗模態分析簡介，國立屏東科技大學實驗模態分析課講義。