臺灣博碩士論文加值系統

車削過程中，顫振的發生常隨工件尺寸與加工位置之變化而改變，本研究分析工件尺寸與加工位置對車削顫振穩態區域之影響以及開發車削線上即時切削顫振抑制系統。研究過程以CNC車床為平台，在不使用頂心輔助的設定下加工S45C中碳鋼棒材，並使用衝擊錘與三軸加速規進行模態測試，取得刀具與工件之頻率響應函數，進而以CutPro軟體模擬以獲得切削穩定圖，分析不同工件直徑與長度以及切削點變化對顫振發生的影響，並實驗驗證模擬方析結果之正確性。在建立線上車削顫振抑制系統方面，本研究將加速規架設於刀塔安座之側邊，利用加工振動訊號之標準差判別顫振之發生，並以轉速修改的方式進行顫振之抑制。
　　研究分析結果顯示，在工件尺寸對顫振穩態區域影響分析中，相同直徑工件對應之臨界切深值隨其長度尺寸降低而增加，顫振穩態圖中加工穩定參數區間間隔則隨之減小；另一方面，工件長度相同對應之臨界切深值隨直徑之增加而增加，顫振穩態圖中加工穩定參數區間間隔則視各自然頻率數值變化而未有絕對趨勢。在加工位置對顫振穩態區域影響分析中，隨著加工進行，臨界切深數值隨著加工點位置移往工件夾頭而增加，而臨界穩態邊界之耳垂對應主軸轉速之數值則無明顯變化。最後，實驗驗證由CutPro 獲得之顫振穩態邊界，不同之轉速其誤差值約在10% 至75%。
在建立線上車削顫振及時抑制系統的部分，本研究所建立之系統在外徑車削中可進行增速與降速抑制，成功偵測與抑制車削顫振的發生；在內孔車削中測試中，則以降速抑制的方式進行抑制驗證，可於2秒內將顫振完全移除。

In turning process, the occurring of chatter will vary with the change of workpiece size and the cutting location. In this study, the effects of workpiece size and cutting location on chatter were analyzed, as well as the development of a chatter monitoring and control system. To obtain the Lobe Stability Diagram for chatter analysis, the model tests on workpiece with various sizse and tool/workpeice contact locations were conducted first, and the CutPro software were then used for obtaining the stability diagram. Finally, an experiments were conducted to verify the the boundary of the stability of cutting obtained from the CutPro software. In the development of the chatter monitoring and control system, an accelerometer was installed close to the turret in lathe, and the standard deviation of obtained vibration signal is used for detecting the chatter, and the change of cutting speed then be conducted by controller to avoid the chatter.
The results show that increase of the workpiece length and the reduction of wokpeice diameter will reduce the critical depth of cut for chatter. In the change of cutting location along the workpiece, the critical depth of cut will decrease as the cutting location away from the chuck. In the experimental verification of Lobe Stability Diagram obtained from CutPro software, 10% to 75% error can be obtained with various cutting speed.
In the verification of the developed real-time on line chatter monitoring and control, the system can detect and surpass the chatter successfully in turning and boring.

摘要 I
Abstract II
目錄 III
圖目錄 V
表目錄 IX
第一章 緒論 1
1.1前言 1
1.2文獻回顧 2
1.2.1 切削顫振之影響研究 2
1.2.2 切削顫振穩態預測之發展 2
1.2.3 顫振抑制方法 3
1.2.4線上顫振抑制系統發展 3
1.3研究目的與內容 4
1.4本文架構 4
第二章 研究方法與基本理論 6
2.1自激性顫振基本理論與預測 6
2.2頻率響應函數 9
2.2.1敲擊法介紹 10
第三章 線上即時車削顫振抑制系統 11
3.1顫振加工訊號量測 11
3.2 顫振判別法則建立 12
3.3 顫振抑制法則建立 12
3.4 控制器資訊與命令傳輸 14
3.5 顫振警示 15
第四章 實驗設計 16
4.1工件尺寸對切削顫振穩態區域影響實驗設計 16
4.2加工位置對切削顫振穩態區域影響實驗設計 18
4.3顫振抑制系統驗證實驗設計 19
第五章 研究成果與討論 22
5.1工件尺寸對切削顫振穩態區域影響分析 22
5.1.1工件尺寸對頻率響應函數(FRF)之影響 23
5.1.2工件尺寸對切削顫振穩態圖(SLD)之影響討論 26
5.2 加工位置對切削顫振穩態區域影響分析 30
5.2.1加工位置對頻率響應函數(FRF)之影響討論 30
5.2.2加工位置對切削顫振穩態圖(SLD)之影響討論 31
5.3工件尺寸與加工位置對顫振穩態參數影響分析結果驗證 33
5.3.1直徑40m度150mm之工件驗證結果 34
5.3.2直徑40mm度180mm之工件驗證結果 37
5.3.3直徑40mm長度200mm之工件驗證結果 39
5.3.4直徑35mm長度180mm之工件驗證結果 44
5.3.5直徑35mm長度150mm之工件驗證結果 46
5.4 顫振抑制系統驗證實驗結果 49
5.4.1顫振加工訊號量測分析 49
5.4.2外徑車削增速抑制之成果 53
5.4.3外徑車削降速抑制之成果 55
5.4.4 內孔車削增速抑制之成果 57
5.4.5 Servbox DAQ存儲資料效率修正 59
第六章 結論與未來展望 60
6.1結論 60
6.2未來展望 61
參考文獻 62

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