臺灣博碩士論文加值系統

精密工具製造公司常常認為他們的產品有優良的精準度在市場上競爭，如果要達到這目標要不斷的改進該工具的設計與製造方法。本研究的目標是為了優化倒角刀片的設計，倒角是個在任何機械加工行業中用於去毛刺或去除工件上的尖銳邊緣，倒角表面的主要目的是要得到良好的表面光潔度且無毛邊。本研究針對幾何形狀刀片對倒角表面光潔度和毛邊的影響，運用了 Taguchi L9 正交陣列設計。這理論所考慮的控制因素是前角，刃帶寬度和珩磨半徑，根據田口設計，所有實驗均使用兩組工加參數進行。所用的工加參數是6000 rpm 的主軸轉速，對於 C2倒角尺寸，進給速度為400 mm / min。C3倒角尺寸之進給速度為200 mm / min 。結果發現，前角為18º，刃帶寬度為0.2 mm，珩磨半徑為20 µm 的幾何形狀刀片可產生具有良好表面光潔度和無毛邊。

Precision tool manufacturing companies always assume to have their products with high precision to compete with other companies in the market. This requires constant improvements in the tool design and manufacturing process. The aim of this study is to optimize the tool design of the chamfering insert. Chamfering is a basic process used in any machining industry for the deburring or removal of sharp edges on the workpiece. The main aspect of a chamfered surface is to have an excellent surface finish with no raw edge. This study investigates the effect of insert geometry on the chamfered surface finish and the raw edge by the use of Taguchi L9 orthogonal array design. Control factors considered in this thesis are the rake angle, the land width, and the honing radius. All the experiments were conducted with two sets of process parameters as per Taguchi design. The process parameters used are 6000 rpm spindle speed, 400 mm/min feed rate for the chamfer size of C2, and 200 mm/min for the chamfer size of C3. The results were found to be that insert geometry with a rake of 18 °, a land width of 0.2 mm, and a honing radius of 20 µm produces a chamfered surface with good surface finish and no raw edge.

English Abstract...............................................................i
Chinese Abstract...............................................................ii
Acknowledgement................................................................iii
Table of Contents..............................................................iv
List of Tables.................................................................vii
List of Figures................................................................ix
List of Abbreviations..........................................................xii
List of Symbols................................................................xiv

CHAPTER 1 INTRODUCTION...................................................1
1.1 Introduction...................................................1
1.2 Problem Statement..............................................1
1.3 Research Goals and Objectives..................................2
1.4 Scope of this Research.........................................2
1.5 Thesis Organization Structure..................................3
1.6 Research Outline...............................................4

CHAPTER 2 BASIC THEORY...................................................5
2.1 Introduction...................................................5
2.2 Milling........................................................5
2.2.1 Thermal Shock..................................................5
2.2.2 Chamfering Process.............................................6
2.3 Insert Technology..............................................7
2.3.1 Insert Geometry................................................7
2.3.1.1 Chip Breaker...................................................8
2.3.1.2 Land Width and Edge Honing.....................................8
2.3.1.3 Rake Angle.....................................................9
2.3.2 ISO Milling Insert Designation Chart...........................10
2.4 Cutting Tool Coating...........................................13
2.5 Cutting Tool Materials.........................................15

CHAPTER 3 METHODOLOGY....................................................17
3.1 Introduction...................................................17
3.2 Planning Phase.................................................18
3.2.1 Selection of Parameters and it’s Levels........................18
3.2.2 Arrange of Experiments using Taguchi Orthogonal Array..........19
3.3 Test Insert Production Process.................................20
3.3.1 Designing Stage................................................21
3.3.2 Manufacturing Stage............................................23
3.3.2.1 Raw Material Preparation.......................................23
3.3.2.2 Peripheral Grinding Process....................................24
3.3.2.3 Wire EDM Process...............................................24
3.3.2.4 Cutting Edge Preparation Process...............................25
3.3.2.5 Insert Naming and Coating Process..............................27
3.4 Verification of Insert Geometry................................27
3.5 Materials......................................................28
3.5.1 Workpiece Material Properties..................................28
3.5.2 Cutting Insert Material Properties.............................29
3.6 Cutting Tools..................................................31
3.6.1 Chamfering Cutter..............................................32
3.6.2 Face Milling Cutter............................................33
3.7 Equipment’s Used...............................................34
3.7.1 Machine Tool...................................................34
3.7.2 Surface Roughness Measuring Instrument.........................35
3.7.3 Keyence One-shot 3D machine....................................37
3.7.4 Yuantai ARCS 2D machine........................................37
3.7.5 Software’s Used................................................38

CHAPTER 4 EXPERIMENTATION & DATA COLLECTION..............................39
4.1 Introduction...................................................39
4.2 Selection of Experimental Parameters...........................39
4.3 Conduction of Experiments......................................41

CHAPTER 5 RESULTS & DISCUSSION...........................................46
5.1 Taguchi Analysis...............................................46
5.2 S/N Ratio......................................................48
5.2.1 S/N Sample Calculations........................................49
5.3 Analysis of Variance...........................................51
5.3.1 Interaction of Control Factors.................................54
5.4 Response Optimization..........................................56
5.5 Analysis of Experimental Data..................................58

CHAPTER 6 CONCLUSION.....................................................64
REFERENCES.....................................................................66
APPENDIX I.....................................................................70
Extended Abstract..............................................................81

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