臺灣博碩士論文加值系統

鋸帶的磨耗是造成鋸床加工表面品質下降的主因，以往的檢測方法大多等到機台發出明顯的振動或噪音時，才將機台停機進行加工品質檢查，但是此種方法通常發現得太晚進而導致加工品質降低，若能在機台出現輕微異常時就立即發現與處理，利用感測器的檢知，通知操作人員排除異常，不僅能確保產品的加工品質，也能提高生產效率。
本文研究重點主要為探討造成鋸帶壽命衰退的切削磨耗特徵，利用以量測龍門式帶鋸機在長時間切削下，針對S45C材料進行切削加工，在活動鋸臂之徑向黏貼加速規，量測鋸帶鋸切時的振動數據，經由快速傅立葉轉換為頻譜圖進行分析；在鋸臂內以應變規量測，在鋸切時固定銷的應變利用負載公式計算出鋸帶的、鋸切負載；並將與鋸切下的試片進行的歪斜量與表面粗糙度量測，探討隨切削里程所增加的變化與關係進行研究分析，探討鋸帶機在長時間鋸切S45C工件時鋸帶因鋸帶磨耗而導致的鋸切震動增加，鋸切負載變大以及鋸切切片歪斜量變化，來探討更換鋸帶的時機以及建立鋸帶鋸切性能衰退趨勢。在研究實驗中所分析的各項特徵可以發現，切削加工來到700刀之後，鋸切振動與負載明顯升高5~10 %，試片表面的加工表現出現明顯衰退，工件表面也有顯著的犁耕現象，顯示此時為更換鋸帶的最佳時機。

In the deterioration of the surface quality, the deterioration of the band-sawing is the main reason which causes low quality of the machined surface. In the past, we detection methods and stopped the machine to check the processing quality when machine was made obvious vibration or noise. However, is usually found too late, lead to a defected in the material of the processing. If we can used the detection of the sensor and notify the operator to eliminate the abnormality when the machine has a slight abnormality. It can be detected and dealt with immediately which can not only ensure the processing quality of the product and improve the production efficiency.
This study focuses on explore for the wear degradation assessment of band-sawing by using signal processing and analysis under S45C materials in long-term cutting operations. This paper uses fast Fourier transform (FFT) and cutting load formula to respectively process vibrational signals and machined cutting load. With the data analysis ability of these two models and measure the cutting skew value and surface roughness, discuss the change and relationship in the cutting process. According to the characteristics analyzed in the research experiment, we find that the wear degradation of the band-sawing will cause higher lateral vibration on the blade .With the result of this study, we can be found that after the cutting process 700 knives; when the cumulative cutting area is 123,638 〖cm〗^2, the sawing vibration and skew load value raised by 5~10%, and plowing appearance on the surface of the workpiece. By observing the fitting parameters of the data base, indicating that is a right time to replace the band-sawing.

中文摘要.......i
英文摘要.......ii
誌謝.......iv
目錄.......v
表目錄.......vii
圖目錄.......viii
符號說明.......x
第一章.......1
緒論.......1
1-1 前言.......1
1-2 研究動機與目的.......1
1-3 文獻回顧.......2
1-3-2 訊號量測.......2
1-3-2 訊號處理與分析.......2
1-4 論文架構.......4
第二章 基礎理論.......5
2-1 切削過程與訊號監測.......5
2-2切削理論.......5
2-3 鋸帶.......6
2-3-1 鋸帶結構.......9
2-3-2 鋸帶規格.......10
2-4 數位訊號處理 (Digital Signal Processing).......10
2-4-1 取樣定理 (Sampling Theorem).......10
2-4-2 訊號前處理.......11
2-4-3 訊號頻域轉換.......11
2-4-4 快速傅立葉轉換 (Fast Fourier Transform, FFT.......12
2-4-5 時頻分析 (Time-frequency analysis).......13
2-5 回歸分析 (Regression Analysis).......13
2-5-1 曲線擬合 (Curve Fitting).......14
2-6 均方根法 (Root Mean Square, RMS).......14
2-7 梯形積分法 (Trapezoidal Rule).......15
2-8 鋸帶速度與鋸床切削率公式推導.......15
2-8-1 切削力公式推導與計算.......16
2-8-2 銷之慣性矩計算.......16
2-9 表面形貌分析 (Morphology & Topography).......18
2-9-1 中心線平均粗度 (Center line average roughness ; Average roughness value,Ra).......18
2-9-2 最大粗糙度 (Rmax).......18
2-9-3 犁耕現象.......19
第三章 研究方法與實驗規劃.......20
3-1研究流程.......20
3-2 實驗設備與配置.......21
3-2-1 實驗設備與配置.......21
3-3 訊號擷取.......22
3-3-1 感測器之裝設.......22
3-3-2 加速規訊號之擷取.......27
3-3-3 應變規訊號之擷取.......28
3-4 實驗規劃.......30
3-4-1 實驗流程.......30
3-4-2 切削實驗參數.......30
3-4-3 訊號分析流程.......31
第四章 實驗結果與討論.......32
4-1 振動分析.......32
4-1-1切削振動量測與頻譜分析.......32
4-1-2振動RMS值.......39
4-2加工表面特性分析.......40
4-2-1表面粗糙度分析.......40
4-2-2振動能量與表面粗糙度分析.......43
4-3切削歪斜分析.......48
4-3-1切削歪斜量與振動RMS值分析.......49
4-4切削下壓力分析.......50
4-4-1 切削力負載.......50
4-4-2 切削力負載、切削振動與切削歪斜分析.......52
第五章 結論.......54
5-1 結論.......54
5-2 未來展望.......54
參考文獻.......55
Extended Abstract.......57

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