臺灣博碩士論文加值系統

線切割放電加工(Wire-EDM)乃為模具產業非常重要加工環節程序，同時也是高硬度材料及需高精密度要求之最佳加工選擇。線切割放電加工最佳化參數研究已不勝枚舉，但其更深入探討加工刀數參數最佳化研究卻寥寥無幾，故本研究針對線切割放電加工第二刀加工製程參數最佳化進行實驗規劃設計，該實驗採兩階段實驗；首先採用二水準部分因子設計(Two-Level Fractional Factorial Design)，進行因子篩選，接著實驗分析找出較為顯著因子，最後進行應用反應曲面法(Response Surface Methodology, RSM)配置面中心中央合成設計(Face-Centered Central Composite Design, FCCCD)來評估經篩選過後之重要影響因子及水準之期望範圍間品質反應特性。實驗過程中潛伏的干擾因子會影響實驗結果，雖本研究已採隨機化設計，但干擾因子為未知且無法控制或已知可控制，本研究將並配置不完全區集設計(Balanced Incomplete Block Design, BIBD)技巧來處理消除實驗過程中干擾因子及趨勢效應，而求出對線切割放電加工最佳化製程參數。

本研究之實驗因子選擇：開路電壓、短路放電時間、放電時間、短路休止時間、休止時間、伺服參考電壓、進給倍率及線張力；而實驗探討品質特性為表面粗糙度、尺寸精密度與加工時間。經由實驗規劃設計流程完成實驗，並加以驗證後得知：K340模具鋼線切割放電加工最佳化加工參數為開路電壓7 V、放電時間1 、休止時間12 、短路放電時間1 、短路休止時間15 s、伺服參考電壓40 V、進給倍率12與線張力8 g；在室溫加工環境下34 ℃，最佳化品質特性則為表面粗糙度2.3 、尺寸精密度10 mm及加工所需時間194 sec；若在標準加工環境溫度下25 ℃，則最佳化品質特性則為表面粗糙度1.92 、尺寸精密度10 mm及加工所需時間186 sec。

Wire-EDM is a very important manufacturing process in mold industry and it is for the best choice for high hardness material and high-precision requirement. The research in line cutting optimization parameters is numerous, but in-depth explorations in the optimization of maching number are few, so in this research parameters optimization experiment for Wire-EDM second blade machining process is planned and designed. The study adopted a two-stage experiment. The first part uses Two-Level Fractional Factorial Design for factor screening, followed by experimental analysis to identify the more significant factor and finally the application of Response surface methodology (RSM) and Face-Centered Central Composite Design (FCCCD) to assess the inter-important factor by screening the expected range and the level of quality of response characteristics. The latent interference factor will affect the results, though this study adopted the randomized design, but the interference factor is unknown and cannot control or known to be controlled. This study configures Balanced Incomplete Block Design (BIBD) techniques to deal with the elimination of interference factors during the experiment and the trend effect, while obtaining optimization parameters for the wire-cut electric discharge machining process.
Control facfor of this study: the open circuit voltage, short circuit discharge time, discharge time, short rest time, rest time, a servo reference voltage, the feed rate and the wire tension along with the experiments to explore the quality characteristics of the surface roughness, dimensions and processing time. After the completion of the experiment and verified with K340 die and steel Wire-EDM, the optimized processing parameters were open circuit voltage of 7 V, discharge time of 1 , short rest time of 15 s, servo reference voltage of 40 V, feed rate of 12 and the thread tension of 8 g. For the working environment at room temperature of 34 ℃, the optimized quality characteristics was the surface roughness of 2.3 , for the size of 10 mm and the required precision machining time was 194 sec. In the working environment with the standard ambient temperature of 25 ℃, the optimization quality characteristics was the surface roughness of 1.92 for the size of 10 mm and the required precision machining time was 186 sec.

摘要 I
Abstract III
致 謝 V
目 錄 VII
表目錄 X
圖目錄 XIV
符號說明 XXI
第一章 緒論 1
1.1研究背景 1
1.2研究動機 2
1.3文獻回顧 2
1.3.1放電加工起源 2
1.3.2線切割放電加工發展與應用 3
1.3.3線切割放電加工製程最佳化研究 4
1.4研究目的 14
1.5本文架構 14
第二章 加工原理與實驗設計基礎理論 17
2.1放電加工原理簡介 17
2.1.1放電加工材料移除過程 18
2.1.2放電現象轉換過程 19
2.1.3放電火花結構 20
2.1.4放電加工放電迴路模式 21
2.1.5放電加工放電控制模式 23
2.2線切割放電加工簡介 25
2.2.1線切割放電加工參數 26
2.2.1.1機械參數 26
2.2.1.2電能參數 27
2.2.2線切割放電加工產出品質特性 28
2.3實驗設計法簡介 33
2.3.1基礎統計檢定理論 34
2.3.2迴歸分析 35
2.3.3願望函數 36
2.3.4區集劃分設計 39
2.4二水準部分因子設計 40
2.4.1二水準部分因子基本原理與定義 40
2.4.2解析度設計 40
2.5反應曲面法 41
2.5.1反應曲面法基本原理與定義 41
2.5.2中央合成設計法 43
第三章 研究方法 46
3.1實驗步驟規劃流程 46
3.2實驗材料 53
3.3實驗設備儀器 55
3.3.1 線切割放電加工實驗機台 55
3.3.2 高精度三次元量測儀 56
3.3.3表面粗糙儀 56
3.3.4厚薄規 56
3.3.5水平儀 57
3.3.6 K-200洗淨劑 57
3.4 線切割放電加工實驗加工程式撰寫 60
3.5實驗工件設計、加工路徑 61
3.6實驗分析軟體 63
第四章 結果與討論 64
4.1二水準部分因子設計結果分析與討論 64
4.1.1加工參數對表面粗糙度重要因子篩選結果 68
4.1.2加工參數對尺寸精密度重要因子篩選結果 79
4.1.3加工參數對材料加工時間重要因子篩選結果 91
4.1.4加工參數之重要因子篩選結果與最佳化 103
4.2反應曲面法結果分析與討論 113
4.2.1加工參數對表面粗糙度之影響 118
4.2.2加工參數對尺寸精密度之影響 126
4.2.3加工參數對材料加工時間之影響 135
4.2.4加工參數最佳化與實驗驗證 145
第五章 結論與未來展望 155
5.1結論 155
5.2未來展望 156
參考文獻 157
附錄一、K340材質證明 162
附錄二、K340熱處理檢驗報告書 164
附錄三、Wire-EDM Q4025L機台詳細規格 165
附錄四、高精度三次元量測儀詳細規格表 167
附錄五、表面粗糙儀詳細規格表 168
附錄六、各 設計別名關係與結構 169
附錄七、Critical Values of the F-Distribution 172
附錄八、Wire-EDM粗切一刀下料尺寸 175
作者介紹 184

[1]Bo-Sheng Cheng, Tsung-Sheng Sheu, Herchang Ay, 2015, A Study of Difference Analysis for Optimal Parameters by Using Blocking Design, Conference on Precision Machinery and Manufacturing Technology, Kenting .
[2]鹽田泰仁，蕭旭烈，1986，線切割放電加工實務，復文書局，台南。
[3]S. Webzell, 2001, That first step into EDM, in: Machinery, 159, (4040) Findlay Publications Ltd, Kent, UK, pp. 41.
[4]Anonymous, 1965, History and development in the Techniques and Practice of Spark Erosion Machining, Sparcatron Limited, Gloucester, UK, pp. 6.
[5]倉藤尚雄，鳳誠三郎，鄒大鈞，1998，工業實用技術─放電加工，復文書局，台南。
[6]K.H. Ho, S.T. Newman, 2003, State of the art electrical discharge machining (EDM), International Journal of Machine Tools and Manufacture, Vol. 43, pp. 1287-1300.
[7]N.J. Lazarenko, B.R., 1943, To invert the effect of wear on electric power contacts, Dissertation of the All-Union Institute for Electro Technique in Moscow/CCCP, Russian.
[8]A.L. Livshits, 1960, Introduction, in Electro-erosion Machining of Metals, Department of Scientific & Industrial Research, Butterworth & Co., London.
[9]Jameson, E.C., 2001, Description and Development of Electrical Discharge Machining, Society of Manufacturing Engineers, Dearbern, Michigan, USA.
[10]B.R., N.J. Lazarenko, 1944, Electrical Erosion of Metals in Russian: Gosenergoisdat Leningrad, pp. 27.
[11]Houman, L., 1983, Total EDM in Jameson (Ed), Electrical Discharge Machining: Tooling, Methods and Applications, SME, Dearborn, Michigan, pp. 5-19.
[12]Abu Zeid O.A., 1997, On the effect of electro discharge machining parameters on the fatigue life of AISI D6 tool steel, Journal of Materials Processing Technology, Vol. 68, pp. 27–32.
[13]斎騰長男，賴耿陽，1998，放電加工機活用，復漢出版社，台南市。
[14]井上潔，黃錦鐘，1998，放電加工，高立圖書有限公司，台北市。
[15]斎騰長男，蘇品書，1984，線切割放電加工，復漢出版社，台南市。
[16]清川盛雄，林維新，林永憲，1993，尖端放電加工，松祿文化事業股份有限公司，台北市。
[17]黃錦鐘，1985，放電加工技術實例，全華科技圖書股份有限公司，台北市。
[18]K.H. Ho, S.T. Newman, S. Rahimifard, R.D. Allen, 2004, State of the art in wire electrical discharge machining (WEDM), International Journal of Machine Tools & Manufacture, Vol. 44, pp. 1247–1259.
[19]W.Y. Peng, Y.S. Liao, 2003, Study of electrical discharge machining technology for slicing silicon ingots, Journal of Materials Processing Technology, Vol. 140, pp. 274-279.
[20]Takayuki Tani, Yasushi Fukuzawa, Naotake Mohri, Nagao Saito, Masaaki Okada, 2004, Machining phenomena in WEDM of insulating ceramics, Journal of Materials Processing Technology, Vol. 149, pp. 124-128.
[21]Eberhard Bamberg, Dinesh Rakwal, 2008, Experimental investigation of wire electrical discharge machining of gallium-doped germanium, Journal of Materials Processing Technology, Vol. 197, pp. 419-427.
[22]Y.S. Liao, J.T. Huang, H.C. Su, 1997, A study on the machining-parameters optimization of wire electrical discharge machining, Journal of Materials Processing Technology, Vol. 71, pp. 487- 493.
[23]J.T. Huang, Y.S. Liao, W.J. Hsue, 1999, Determination of finish-cutting operation number and machining-parameters setting in wire electrical discharge machining, Journal of Materials Processing Technology, Vol. 87, pp. 69- 81.
[24]J. T. Huang , Y. S. Liao, 20003, Optimization of machining parameters of Wire-EDM based on Grey relational and statistical analyses, International Journal of Production Research, Vol. 41, pp. 1707- 1720.
[25]Nihat Tosun, Can Cogun, Gul Tosun, 2004, A study on kerf and material removal rate in wire electrical discharge machining based on Taguchi method, Journal of Materials Processing Technology, Vol. 152, pp. 316- 322.
[26]M.S. Hewidy, T.A. El-Taweel, M.F. El-Safty, 2005, Modelling the machining parameters of wire electrical discharge machining of Inconel 601 using RSM, Journal of Materials Processing Technology, Vol. 169, pp. 328- 336.
[27]Ko-Ta Chiang, Fu-Ping Chang, 2006, Optimization of the WEDM process of particle-reinforced material with multiple performance characteristics using grey relational analysis, Journal of Materials Processing Technology, Vol. 180, pp. 96-101.
[28] K. Kanlayasiri, S. Boonmung, 2007, Effects of wire-EDM machining variables on surface roughness of newly developed DC 53 die steel: Design of experiments and regression model, Journal of Materials Processing Technology, Vol. 192-193, pp. 459-464.
[29]S. S. Mahapatra, Amar Patnaik, 2007, Optimization of wire electrical discharge machining (WEDM) process parameters using Taguchi method, The International Journal of Advanced Manufacturing Technology, Vol. 34, pp. 911-925.
[30]R. Ramakrishnan, L. Karunamoorthy, 2008, Modeling and multi-response optimization of Inconel 718 on machining of CNC WEDM process, Journal of Materials Processing Technology, Vol. 207, pp. 343-349.
[31]S. Sarkar, M. Sekh, S. Mitra, B. Bhattacharyya, 2008, Modeling and optimization of wire electrical discharge machining of γ-TiAl in trim cutting operation, Journal of Materials Processing Technology, Vol. 205, pp. 376-387.
[32]Kamal Jangra, Sandeep Grover, Aman Aggarwal, 2011, Simultaneous optimization of material removal rate and surface roughness for WEDM of WCCo composite using grey relational analysis along with Taguchi method, International Journal of Industrial Engineering Computations, Vol. 2, pp. 479-490.
[33]Po-Huai Yu, Yang-Xin Lin, Hsiang-Kuo Lee, Chao-Chuang Mai, Biing-Hwa Yan, 2011, Improvement of wire electrical discharge machining efficiency in machining polycrystalline silicon with auxiliary-pulse voltage supply, The International Journal of Advanced Manufacturing Technology, Vol. 57, pp. 991-1001.
[34]康耀鴻，鄭嘉敏，陳萬億，2012，反應曲面法及混和粒子群應用於微細線切割放電加工表面粗糙度最佳化製程參數之研究，精密製造研討會。
[35]Kannachai Kanlayasiri, Prajak Jattakul, 2013, Simultaneous optimization of dimensional accuracy and surface roughness for finishing cut of wire-EDMed K460 tool steel, Precision Engineering, Vol. 37, pp. 556-561.
[36]Anish Kumar, Vinod Kumar, Jatinder Kumar, 2013, Multi-response optimization of process parameters based on response surface methodology for pure titanium using WEDM process, The International Journal of Advanced Manufacturing Technology, Vol. 68, pp. 2645-2668.
[37]Amitesh Goswami, Jatinder Kumar, 2014, Optimization in wire-cut EDM of Nimonic-80A using Taguchi's approach and utility concept, Engineering Science and Technology, an International Journal, Vol. 17, pp. 236-246.
[38]Saurabh Chhabra, Deepak Gupta, Parveen Yadav, 2014, Optimizing the Process Parameters of WEDM using Taguchi Technique on P-21 die steel, International Journal of Innovative Research in Science, Engineering and Technology, Vol. 3, pp. 14815-14821.
[39]Anoop Mathew Kurian, Dr. Binu C.Yeldose, Ernest Markose Mathew, 2014, Effect of Wire EDM Parameters on Surface Roughness of Stainless Steel 15-5 PH, International Journal of Engineering and Innovative Technology, Vol. 4, pp. 87-90.
[40]Rupesh Chalisgaonkar , Jatinder Kumar, 2015, Multi-response optimization and modeling of trim cut WEDM operation of commercially pure titanium (CPTi) considering multiple user's preferences, Engineering Science and Technology, an International Journal, Vol. 18, pp. 125-134.
[41]Ravindranadh Bobbili, V. Madhu, A.K. Gogia, 2015, Multi response optimization of wire-EDM process parameters of ballistic grade aluminium alloy, Engineering Science and Technology, an International Journal, In Press, Corrected Proof.
[42]謝明樺，2009，純鎢材料之線切割放電加工製程參數最佳化研究，明新科技大學，精密機電工程研究所，碩士論文。
[43]陳伊衔，2013，微細線放電偶角過切之研究，國立高雄應用科技大學，模具工程系碩士班，碩士論文。
[44]張瑞慶，2000，非傳統加工，高立圖書有限公司，台北市。
[45]許坤明，2010，非傳統加工，全華圖書股份有限公司，台北縣土城市。
[46]董光雄，1999，放電加工，復文書局，台南市。
[47]鄒大鈞，1998，工業實驗技術-放電加工，復漢出版社有限公司，台南市。
[48]陳竹男，1981，放電加工原理-技術，建宏書局，台北市。
[49]金屬工業發展中心，1982，工具機手冊之(六十八)放電加工，經濟部國際貿易局，台北市。
[50]張渭川，2001，圖解放電加工的結構與實用技術，全華科技圖書股份有限公司，台北市。
[51]Ivano Beltrami, Axel Bertholds, Dirk Dauw, 1996, A simplified post process for wire cut EDM, Journal of Materials Processing Technology, Vol. 58, pp. 385-389.
[52]R. A. Fisher, 1920, A Mathematical Examination of the Methods of Determining the Accuracy of an Observation by the Mean Error, and by the Mean Square Error, Monthly Notes of the Royal Astronomical Society, Vol. 80, pp. 758-770.
[53]W. Djoudi, F. A. Benissad, S. B. Bacha, 2007, Optimization of Copper Cementation Process by Iron Using Central Composite Design Experiments, Chemical Engineering Journal ,Vol. 133, pp. 1–6.
[54]D. C. Montgomery, 2012, Design and Analysis of Experiments, Wiley, 8 edition.
[55]陳可杰，黃聯海，李婉怡，2013，統計學，滄海圖書資訊股份有限公司，新北市。
[56]林惠玲，陳正倉，2012，應用統計學(四版修訂版)，雙葉書廊股份有限公司，台北市。
[57]黎正中，2012，實驗設計與分析，高立圖書有限公司，新北市。
[58]蘇朝墩，2013，品質工程：線外方法與應用，前程文化事業有限公司，新北市。
[59]葉怡成，2005，實驗計劃法─製程與產品最佳化，五南圖書出版股份有限公司，台北市。
[60]葉怡成，2009，高等實驗計劃，五南圖書出版股份有限公司，台北市。
[61]林李旺，2013，突破品質水準─實驗設計與田口方法之實務應用，全華圖書股份有限公司，新北市。
[62]G. E. P. Box, K. B. Wilson, 1951, On the Experimental Attainment of Optimum Conditions, Journal of the Royal Statistical Society, Series B, Vol. 13, pp. 1-45.
[63]R. H. Myers and D. C. Montgomery, 2009, Response Surface Methodology: Process and Product Optimization Using Designed Experiments, Wiley, 3 edition.
[64]D. C. Montgomery, G. C. Runger , 2010, Applied Statistics and Probability for Engineers, Wiley, 5 edition.