臺灣博碩士論文加值系統

影響刀具的磨耗和工件表面的粗糙度的因子有切削力、切屑形成的形狀、切削熱和局部應力集中等因子，如果能掌握這些因子有助於改善加工品質提高切削效率及降低成本。本研究提出帶鋸刀具幾何結構的切削因子，模擬與改善切削過程中的加工特性，並探討不同切齒種類對鋸削的行為之影響，並分別由不同的製程參數，如鍍層參數、切削速度及進給等，也推導出各因子之刀具壽命方程式。此外，本研究運用的數學方法，包含分形微分方程式、有限元素法、h-自適應性模型和多齒切削改善率模型。經由本論文模擬結果顯示，在鍍層0.6 µm之TiN鍍層，會有較佳的抗磨耗特性，在高速切削時，最大可增進13%的切削改善率；經由單齒切削速度為V=60 m/min時，鍍層0.2~0.6 µm較未鍍層的切齒，最高溫度有顯著的下降平均單齒切削力些微降低；切齒切削速度為V=120 m/min時，鍍層0.6 µm較未鍍層可使溫度下降13%且切削力無明顯變化，表面精度在容許誤差之內。此外，藉由本研究所提之刀具壽命方程式能有效預測鋸帶之切削性能，來因應現今追求之加工效能之提升，作為實際加工時之參考依據。

The factors that influence the tool wear and the surface roughness include the cutting force, the chip shape, the cutting heat, local stress concentration and so on. If these factors can be controlled, then great contributions will be made to improving processing quality, raising cutting efficiency and reducing the cost. This research puts forward the cutting factors of the geometric structure of the band saw cutter, simulates and improves the processing characteristics during the cutting process, discusses the impact of different cutting types on sawing as well as deriving the equation of tool life of different factors by taking advantage of different process parameters such as coating parameters, cutting speed and cutting feed. Additionally, the mathematical methods used in this research include fractal differential equation, finite element method, h- adaptive model and multi tooth cutting improvement rate model. This research’s simulation results show that the wear resistance property is better at coating TiN of coating 0.6 µm. Under high-speed cutting, the cutting improvement rate can increase by 13% at most. When the single tooth cutting speed is 60 m/min, comparing with non-coating cutting tooth, coating 0.2~0.6 µm’s highest temperature decreases obviously and the cutting force of single tooth also decreases a little bit. When the single tooth cutting speed is 120 m/min, comparing with non-coating cutting tooth, coating 0.6µm can make the temperature decrease by 13% with no obvious change in cutting force and the surface accuracy is within the error. In addition, the equation of tool life put forward by this research can effectively predict the cutting performance of the band saw so as to improve the processing efficiency and serve as the reference of actual processing.

目錄
摘要 I
Abstract II
誌謝 III
目錄 IV
圖目錄 VI
表目錄 VIII
符號說明 IX
第一章 緒論 1
1-1 前言 1
1-2 研究動機與目的 2
1-3 文獻回顧 3
1-4 論文架構 6
第二章 理論探討 7
2-1 切削理論 7
2-1-1 切削學分析 8
2-1-2 切削溫度 13
2-1-3 刀具壽命與刀具磨耗 14
2-2 FEM模型理論 18
2-3 以切削係數方程式推導 20
第三章 研究方法 23
3-1 研究流程 23
3-2 邊界條件設定 26
3-3 帶鋸切削模擬方法 27
3-3-1 準靜態模擬方法 27
3-3-2 FEM數值模擬方法 29
3-4 帶鋸切削實驗規劃 31
3-4-1 實驗機台及儀器 31
3-4-2 實驗量測位置與方法 33
第四章 結果與討論 34
4-1 帶鋸準靜態模擬 34
4-2 帶鋸FEM數值分析 37
4-2-1 溫度與切削力的關係 37
4-2-2 進給對溫度與切削力分析 50
4-3 刀具壽命分析 55
4-3-1 刀具壽命與進給分析 56
4-3-2 刀具壽命與鍍層厚度分析 58
4-3-3 正規化平均切削力與進給分析 59
4-4 切削振動能量實驗分析 61
第五章 結論與未來展望 63
5-1結論 63
5-2 未來展望 64
參考文獻 65

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