臺灣博碩士論文加值系統

碳纖維增強碳化矽複合材料，是藉由碳化矽基體與特定排列角度的碳纖維所結合而成的一種高性能複合材料。具備高強度、高硬度、高韌性、低比重、低熱膨脹係數、抗蠕變、耐磨耗、耐高溫及耐化學腐蝕性等特性，通常運用在高溫的系統中。此材料層與層介面間的結合強度較低，在切削負載的作用下容易產生各種加工缺陷，例如纖維拔出、崩邊及介面破壞等，且加上材料的異向性、不均質性及不同的纖維角度等因素，皆會使得切削過程變得十分複雜。
本文使用PCD銑刀、鑽石磨棒及兩種纖維角度於不同輔助系統下進行碳纖維增強碳化矽複合材銑削及磨削實驗，包含旋轉超音波、雙軸向超音波、三軸超音波、雷射及超音波結合雷射混合輔助之銑削與磨削實驗。第一階段透過田口法直交表加工製程參數的規劃，觀察不同刀具與纖維角度於不同輔助系統下的切削性能及加工表面品質，並比較銑削與磨削的優劣，求得較佳的纖維角度及切削輔助系統進行後續實驗。第二階段使用全因子實驗對碳纖維增強碳化矽複合材進行雷射、最佳超音波結合雷射輔助之銑削實驗，在刀具無明顯磨耗的拘束條件下，以加工完成之表面粗糙度與邊緣形貌為目標函數，求得較佳的製程參數。結果顯示，與無輔助相比，使用超音波輔助加工能提高表面品質、降低切削力、減少加工缺陷及刀具磨耗，其中三軸超音波輔助效果最佳。使用PCD銑刀加工後的材料表面品質較磨棒佳，但刀具壽命比磨棒低。雷射預熱能有效降低材料層間結合強度，並減少切削力。透過實驗中各種情況不同組合下切削性能的交叉比較，可證實雷射結合三軸超音波混合輔助為本文最佳輔助系統，擁有最佳的加工性能，其較佳製程參數之組合為高主軸轉速、低進給率及低切深。

Carbon fiber reinforced silicon carbide (C/SiC) composites is a high-performance composite material that is combined silicon carbide matrix with carbon fibers which have a specific arrangement angle. C/SiC has the characteristics of high strength, high hardness, high toughness, low specific gravity, low thermal expansion coefficient, creep resistance, wear resistance, high temperature resistance and chemical corrosion resistance. Therefore, C/SiC composites are generally used in the high temperature environments. Under the action of cutting loads, machining defects are generated easily due to the low interlayer bonding strength of the composite material during the machining processes. Furthermore, the machining processes will become extremely complicated due to the properties of inhomogeneous, anisotropic, different fiber angles and other factors of the C/SiC composites.
In this study, PCD end mills, diamond electroplated grinding rods and two kinds of fiber orientation angles are used to conduct milling and grinding experiments for C/SiC composites under different assisted systems. These systems consist of rotary ultrasonic, biaxial ultrasonic, a combination of rotary and biaxial ultrasonic (triaxial ultrasonic), laser and a hybrid assisted system that is combined ultrasonic with laser. In the first stage, the processing parameters were planned according to the Taguchi method, the cutting performance and machined surface quality for different cutting-tools and fiber angles under different assisted systems are investigated, and the advantages and disadvantages of milling and grinding are also compared crossly to determine the better fiber angles and proper assisted cutting systems for subsequent experiments. In the second stage, the full factorial design was applied to conduct the laser and hybrid assisted milling experiments on C/SiC composites. And the characteristics of the smaller-the-better in Taguchi method are applied to determine the optimal combination of process parameters for C/SiC composites milling, in which the machined surface roughness and machined defects nearby the edge of the material, and less significant cutting-tool wear are used as the objective function and subjecting constraint, respectively. The results show that the better surface roughness, good tool life, less machining defect and smaller cutting force are obtained by ultrasonic assisted systems as compared with no assistance. The effect of triaxial ultrasonic assisted on cutting-performance is the best one among these ultrasonic assisted systems. The machined surface quality by PCD end mills is better than that of the diamond grinding rods, but the tool life is inferior to that of the diamond grinding rods. The interlayer bonding strength of the composites may be reduced by the laser preheating assisted system and the cutting force may be reduced consequently. Through the cross-comparisons of the cutting performance with different combinations of various situations, it can be confirmed that the hybrid assisted system is the best assisted manner for C/SiC composites milling in this study. The best combination of process parameters obtained in this study is high spindle speed, low feed rate and low cutting depth.

摘要 .................................i
Abstract ........................ii
誌謝 ................................iv
目錄 .................................v
表目錄 ................................vi
圖目錄 ...............................vii
第1章 前言 .........................1
1.1 研究背景 .........................1
1.2 研究動機與目的 .................2
1.3 文獻回顧 .........................3
1.4 論文架構 .........................9
第2章 理論基礎 ........................10
2.1 C/SiC複合材料加工特性 ........10
2.2 纖維切屑成形 ................10
2.3 超音波輔助技術 ................11
2.4 雷射輔助切削技術 ................12
2.5 田口實驗方法 ................13
第3章 實驗方法與規劃 ................15
3.1 工件材料與刀具特性 ........16
3.2 實驗儀器設備與規格 ........18
3.3 實驗方法與執行步驟 ........30
第4章 結果與討論 ................33
4.1 表面粗糙度比較 ................33
4.2 切削力比較 ................42
4.3 C/SiC邊緣形貌比較 ........46
4.4 刀具磨耗比較 ................57
第5章 結論與建議 ................66
參考文獻 ................................67
附錄 ................................70
Extended Abstract ................81

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