臺灣博碩士論文加值系統

隨著汽車、航太工業之蓬勃發展，製造業的競爭越加激烈，對產品的要求不只限於品質提升，對生產速度的要求更加重視。鎳基超合金由於在高溫時仍具有很好的強度，故廣泛的使用於如航空發動機之渦輪葉片、轉子、核能發電廠之渦輪機組件、熱交換器、化學設備等，但是鎳基超合金之高強度、低導熱性、加工硬化等特性導致其切削加工時工具壽命與加工效率比一般材料都要來的低。因此，我將針對Inconel-718 與Mar-247的銑削性做探討，並分別由不同的切削速度、每刃進給、切削深度及實際切削實驗，觀察刀具的磨耗與加工後的表面粗造度與切削溫度進行分析。
在面對Inconel-718 與Mar-247如此難加工之材料，刀具壽命的考量是經濟化加工中重要的關鍵。環顧切削中的影響因子，無論是外在的切削參數與環境設定，或是刀具本身的幾何與材質設定，都會對刀具壽命產生一定程度的影響，但基於實際加工時最重要的加工參數考量，本次實驗中將採用不同披覆材質之碳化鎢刀具，來針對影響刀具壽命最重要的切削參數（切削速度、進給率、切削深度)實驗探討，並利用實驗結果來推演出銑削Inconel-718與Mar-247之刀具壽命公式與最佳銑削參數，並且對切削溫度與各項銑削參數之關係進行研究，進而深入了解Inconel-718與Mar-247的銑削性能，並簡化銑削參數之設定，以因應現今追求加工效能的提升，來作為業界實際加工時之有效參考。

Due to the engineering advancement in modern industries, the competition in manufacturing technologies has been increasingly intense as can be seen in automobile and aerospace industries. Nickel-base super-alloys are widely in the manufacture of components for aircraft turbine engines for cryogenic tankage、 liquid rockets、reciprocating engines、 space vehicles、 heat-treating equipment、 chemical and petro chemical industries because of their ability to retain high strength at elevated temperatures. But, because of its high strength、 poor thermal diffusion and work hardening, the cutting of Nickel-based superalloys results in the life of tools and efficiency of works for the worse Therefore, I would like to discuss about the milling machinability of Inconel-718 and Mar-247 By different cutting experiments on cutting speed, feed per tooth, and depth of cut, We can observe tools wear , surface roughness and cutting temperature to analysis。
The main issue encountered when machining nickel-based superalloy Inconel-718 and Mar-247 is short tool life which is attributed to many factors, not only controllable process parameters but also tool material and geometry. The series tests are carried out using carbide inserts to evaluate the effect of varying cutting speeds, feed rates, cutting depth and tool coating materials on tool wear, tool life, and workpiece surface roughness. Cutting temperature and machining parameters are also considered in this study. Based on experimental data, the similarities and differences between Mar-247 and Inconel-718 are quantitatively compared and explained. The results are expected to contribute to productivity improvement and cycle time reduction in machining Inconel-718 and Mar-247 during the global competition increase.

目 錄
中文摘要……………………………………………………I
英文摘要……………………………………………………II
目錄…………………………………………………………III
圖索引………………………………………………………VI
表索引………………………………………………………X
第一章 緒論……………………………………………….1
1-1研究動機……………………………………………….1
1-2文獻回顧……………………………………………….3
1-2-1刀具材質與刀具壽命 ……………………………..3
1-2-2切削溫度與切削參數設定………………………..12
1-3 研究目的…………………………………………….15
第二章 鎳基超合金介紹 ……………………………...18
2-1 鎳基超合金的發展與應用………………………...18
2-2 鎳基超合金組成元素……………………………….21
2-3 合金組織及影響…………………………………….24
2-4 鎳基超合金的強化機構…………………………….28
2-5 鎳基超合金之切削性質…………………………….31
第三章 刀具材料、磨耗與壽命………………………..35
3-1 刀具材料 …………………….…………………….35
3-2 刀具磨耗理論 ...………………………………….44
3-3 刀具壽命………..………………………………….49
3-4 切削理論...................................53
3-4-1 銑削基本原理…………………………………….53
3-4-2 銑削型式………………………………………….54
3-4-3 切刃之接觸型式………………………………….56
3-4-4 銑削條件………………………………………….57
3-5 表面粗糙度…… …………………………………..58
第四章 切削溫度……………………………………....59
4-1切削熱的來源和傳遞 ..………………………….…59
4-2 切削溫度的量測…………………………………… 61
4-3 切削溫度理論 …………………………………..…65
第五章 實驗設備與方法……………………………..…72
5-1 實驗設備…………………………………………...73
5-2 實驗步驟與方法…………………………………...74
5-3 實驗切削條件規劃 …………………………………77
第六章 實驗結果與討論 ….....………………………81
6-1 刀具磨耗分析……………………………………….81
6-1-1 Inconel-718刀具磨耗與切削速度的關係 …….81
6-1-2 Mar-247刀具磨耗與切削速度的關係 ………….84
6-1-3 Inconel-718刀具磨耗與進給率的關係 ……….88
6-1-4 Mar-247刀具磨耗與進給率的關係……………..90
6-2 刀具壽命分析 ………………………………..…..93
6-2-1 Inconel-718刀具壽命 ………………………...93
6-2-2 Mar-247 刀具壽命 ………………………......95
6-3 表面粗糙度分析 …………………………….…...98
6-4 最適切削溫度實驗式 .......................102
第七章 結論與未來方向……………………………….110
7-1 結論………………………………..………………110
7-2 未來方向....... …………………………………113
參考文獻…………………………………………………115




圖索引
圖1-1 飛機發動機材料分布圖…………………………. 3
圖1-2 刀具壽命影響因子 ……………………………..10
圖1-3 γ'相熱穩定圖............................13
圖2-1 超合金分類示意圖 ……………………………..18
圖2-2 各種耐熱超合金的耐熱溫度變化… …………..19
圖2-3 鎳基超合金之晶粒組織(Mar247).....………..24
圖2-4 (a)γ'相FCC結構 (b)γ〞相BCT結構…... ..25
圖2-5 Inconel 718 析出形態示意圖………………...26
圖2-6 析出物與基地相產生之整合應變……………….28
圖2-7 影響材料加工性的因素………………………….31
圖2-8 切削鎳基合金時刀具之溫度分佈.............34
圖3-1 各種刀具材質性能比較………………………….36
圖3-2 刀具材質的適用切削溫度 ……………………..36
圖3-3 碳化物刀具機械與物理特性 …………………..39
圖3-4 刀具磨耗機構圖………………………………...44
圖3-5 各種磨耗與切削溫度(切削速度)的關係..…...45
圖3-6 刀具磨耗曲線………………………...…….….48
圖3-7 刀具磨耗量測標準..........………………….50
圖3-8 刀具壽命曲線…………………………………….51
圖3-9 順(逆)銑削圖…………………………………….55
圖3-10 平面銑削圖…….................………….56
圖3-11 面銑削之切入角……………………..........57
圖4-1 切削區的三個熱源…………………...........60
圖4-2 產生的熱量與切削厚度關係…………………….60
圖4-3 Two-color pyrometer for measuring the tool-flank temperature in milling of AISI 1045 steel, Ueda et al...........l.....64
圖4-4 剪切面熱源............……………………….66
圖4-5 刀具的徑向磨損與切削路程長度的關係…...…69
圖4-6 由刀具的相對徑向磨損確定最適切削速度…….69
圖4-7 切削溫度固定,進給量與切削速度最佳組合圖…71
圖5-1 銑刀規格………………………………………….73
圖5-2 圓型刀片尺寸示意圖........………………….73
圖5-3 紅外線高溫溫度計.........................74
圖5-4 銑削機構示意圖………………………………….75
圖5-5 刀具磨耗量測位置 ……………………………..76
圖5-6 實驗流程圖.........…………………………..76
圖5-7 實驗條件規劃圖 ………………………………..77
圖5-8 刀具壽命循環示意圖 ………..........……..78
圖5-9 表面粗糙度量測方法 ......................80
圖5-10 表面粗度儀量測狀態示意圖 ………………….80
圖6-1 銑削Inconel-718刀腹磨耗與切削速度的關係…82
圖6-2 (a)~(f) Inconel-718刀具磨耗圖……..………84
圖6-3 凹陷磨耗產生關係圖………………….…......84
圖6-4 銑削Mar-247刀腹磨耗與切削速度的關係 …….86
圖6-5 (a)~(f) Mar-247刀具磨耗圖 ………………...87
圖6-6 鍍層刀具磨耗型態示意 …………………………88
圖6-7 銑削Inconel-718刀腹磨耗與進給率的關係……89
圖6-8 銑削Inconel-718刀具磨耗型態與切削速度、進給率之關係90
圖6-9 銑削Mar-247刀腹磨耗與進給率的關係 ……….91
圖6-10 銑削Mar-247刀具磨耗型態與切削速度、進給率之關係...92
圖6-11 Inconel-718刀具壽命與切削速度之關係…….94
圖6-12 Mar-247刀具壽命與切削速度之關係 ………..96
圖6-13 刀具壽命對應刀具披覆材質對數關係圖 ….…97
圖6-14 刀具壽命對應進給率對數關係圖 …………...98
圖6-15 銑削Inconel-718表面粗糙度與切削速度的關係 …...…100
圖6-16 銑削Mar-247表面粗糙度與切削速度的關係 …………...101
圖6-17 Mar-247表面粗糙度圖 ………………………..………...101
圖6-18 切削Inconel-718時刀具的徑向磨損與切削路程長度關係.103
圖6-19 切削Mar-247時刀具的徑向磨損與切削路程長度關係…..104
圖6-20 銑削Inconel-718之切削溫度與切削速度、進給率、切削深度關係關係.107
圖6-21 銑削Mar-247之切削溫度與切削速度、進給率、切削深度關係關係…….107


表索引
表2-1 Inconel-718與Mar-247化學成分表 ………………. ….21
表2-2 Inconel-718與Mar-247強化特性之比較..............30
表2-3 不同材料之切削性…………........…….…………….32
表3-1 被覆材料之性質…………………………………….….…41
表4-1切削溫度試驗正交表……………………………………...70
表5-1 被覆材料性質介紹 ……………………………….……..73
表5-2 固定時間切削條件設定…………....................78
表5-6 固定長度切削條件設定……....……………………..…79
表6-1 定長度切削Inconel-718時切削速度與刀具磨耗結果…102
表6-2定長度切削Mar-247時切削速度與刀具磨耗結果……….102
表6-3 Inconel-718切削溫度實驗正交表…....………………104
表6-4 Mar-247切削溫度實驗正交表… ……………………….105

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【94】吳江妙和楊志強〝Inconel 718合金高速切削加工的工藝參數優化〞,機械製造47捲第,542期.10/2009中國
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【99】Chu-Pao Kuo, Chi-Der Lin, 〝The Study on the Thermal Characteristic and Cutting Force of Laser-Assisted Machining for Sapphire ( ) Material〞, Journal of Chinese Society of Mechanical Engineers, accepted 2012/05