隨著科技日新月異，工具機產業也朝高速化、高效率、多軸化、高精度、低成本以及智慧化發展，高階工具機為滿足高速化與高精度之整體性能要求，其工具機結構設計得具有足夠的剛性，以達到所要求的精度與穩定性。工具機結構設計直接反應於加工特性，連帶影響成品精度與品質。本文著重於研究五軸工具機結構靜、動剛性、熱變形分析與模態實驗驗證，並進行加工測試。本研究機台主結構分別為底座、立柱、主軸頭、滑軌台、旋轉工作台等，並利用有限元素方法作為結構解析工具，建構五軸工具機模型。後續結合拓樸優化方法將數值量化後，進行結構再設計，進一步實現動態特性的改善，機台加工精度亦可提升。而透過機台結構分析之結果，設計加工實驗，實際進行切削驗證，並藉由輸入切削參數建構表面粗糙度預測模型，本研究提出優化結構設計以改善機台動態特性與結合AIM軟體提供智慧化預測表面粗糙度模型，已滿足未來五軸加工品質的需求。將加工參數透過AIM多項式網路進行運算，建構切削速度、進給速率、徑向切深、軸向切深相對數學關係式，並建構程式碼加載於控制器，相信本研究對於工具機產業朝智慧製造的發展，具有實際助益與技術層面的突破。

With rapid advancements in science and technology, the machine tooling industry has also been developing in terms of tooling speed, efficiency, multiple axes, precision, low cost and intelligent machining. To satisfy the performance requirements of high-speed and high-precision machining, the structural design of the machine tool must be sufficiently sturdy to fulfill rigidity constraints; moreover, it must satisfy the requested precision and stability requirements. The structure of a machine tool directly influences the processing characteristics, which consequently affects the accuracy and quality of the product.
The focus of this study is on investigating static and dynamic rigidity. A thermal deformation analysis is performed and modal experimental verification of the structure of the five-axis machine tool is conducted, and then proceeding process tests. In this study, the main structure of the machine consists of many components including the base, column, spindle head, slide rail table, and rotary table. Finite element method was used as a structural analysis tool to create the model of the five-axis machine tool. Simultaneously, process verification combined with the topological optimization method, to quantify the data and re-design the structure, further enabled the improvement of the dynamic characteristics, and enhanced the machining accuracy of the process. Through machine structure analysis, this study focuses on designing process parameter experiments, verifying the actual cutting process, and using the obtained parameters to construct a surface roughness estimation model. Thereafter, an optimized structural design that improves the dynamic characteristics of the machine is proposed. Finally, in combination with AIM software, an intelligent parameter estimation method for the surface roughness model is developed, which aims to satisfy the quality demands of five-axis machining in the future.
The process parameters were calculated using the AIM polynomial network to construct the relative mathematical relations for cutting speed, feed rate, width of cut, and depth of cut. The construction code was then loaded into the controller.
This research will contribute to moving the machine tooling industry toward smart manufacturing with the respect to technological breakthroughs of the practical benefit.

摘要...i
Abstract...ii
誌謝...iv
目錄...v
表目錄...viii
圖目錄...ix
符號說明 ...xii
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...1
1.4論文大綱...5
第二章 相關理論與實驗設備...7
2.1有限元素法簡介...7
2.1.1有限元素法平衡方程式...8
2.1.2有限元素類別...10
2.1.3有限元素分析重要名詞 ...11
2.2振動與模態基礎理論...13
2.2.1單自由度系統...13
2.2.2實驗模態分析簡介...15
2.2.3模態分析重要名詞...15
2.2.4模態與剛性理論...17
2.3銑削型式及特點...17
2.3.1順銑法...17
2.3.2逆銑法...18
2.4切削加工參數...18
2.4.1切削速度...18
2.4.2每刃進給...19
2.4.3徑向切深與軸向切深...19
2.5 Abductory Induction Mechanism類神經網路...19
2.5.1多項式功能節點介紹...20
2.5.2預測平方誤差(PSE)...21
2.5.3 Complexity Penalty Multiplier (CPM)...23
2.5.4 Overfit Penalty...24
2.5.5 Carving limit...24
2.6實驗設備...24
2.6.1衝擊鎚...24
2.6.2加速規...24
2.6.3頻譜分析儀...25
2.6.4 ME'scope...26
2.6.5靜剛性設備...26
2.6.6有限元素分析軟體 ANSYS...29
2.6.7拓樸優化軟體 HyperWorks...29
2.6.8五軸工具機UX300...30
2.6.9 Surfcorder SE-4000表面粗糙度量測儀...31
2.6.10 Olympus STM 6 高精度工具顯微鏡...32
2.6.11 Abductory Induction Mechanism類神經網路...33
第三章 有限元素分析與實驗驗證...34
3.1有限元素分析...34
3.1.1有限元素模型...34
3.1.2材料性質...34
3.1.3網格化...35
3.1.4收斂性分析...36
3.1.5邊界條件設置...37
3.1.6靜態分析...38
3.1.7模態分析...39
3.1.8頻譜分析...41
3.1.9暫態分析...42
3.1.10熱變形分析 ...42
3.2靜剛性分析及驗證...44
3.2.1靜剛性分析...44
3.2.2靜剛性實驗...45
3.3模態試驗...48
3.3.1五軸工具機佈點規劃...48
3.3.2敲擊試驗...50
3.3.3結構自然頻率分析...52
3.3.4 CAD模型驗證...54
第四章 結構優化 ...56
4.1結構優化設計...56
4.1.1拓樸優化...57
4.1.2結構優化再設計...58
4.2設計變更結果...59
第五章 切削驗證與智慧化...61
5.1加工實驗...61
5.2加工模態驗證...62
5.3智慧化切削實驗設計...63
5.4 Abductory Induction Mechanism多項式網路應用...67
5.5驗證多項式網路模型...68
第六章 結論與未來展望...70
6.1結論...70
6.2未來展望...71
參考文獻...72

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