臺灣博碩士論文加值系統

磁性磨料在磁力研磨拋光中所扮演的角色相當於加工機中之刀具tools，為磁力研磨拋光極為重要的加工要素。磁性研磨材料必須具備有被磁化性質及有研磨能力的複合磨料，磁化性良好的物質如鐵、鈷、鎳..等；研磨材的種類如氧化鋁、碳化矽、氮化硼、碳化硼、鑽石粉末...等。由於磁性磨料所需之製造設備昂貴，製造過程亦需要特殊的專業技術，導致目前國外進口磁性磨料價格居高不下。

為探討燒結後磁性磨料之結合度的狀況，及其應用於不�袗�SUS304之表面粗糙度及材料移除率，本研究採用真空燒結技術並配合田口實驗法進行燒結實驗規劃，製造結合鐵與氧化鋁之磁性磨料，以獲得鐵粉粒度、氧化鋁粉粒度、成份比例、壓製成形壓力、PVA黏結劑、燒結溫度、加熱時間等七個不同因子之最佳參數組合，並以SEM搭配EDS分析燒結後之磁性磨料。經由實驗結果發現自行研發的磁性磨料經過實際的拋光驗證，已能將不�袗�SUS304之表面拋光至鏡面程度（Ra0.018μm），足以媲美日本進口之磁性磨料，初步已展現出良好的研究成果。

本研究之主要目的係利用真空燒結技術，進行研發更優質、更耐磨且低成本的磁性磨料，亦即磁性磨料之研製及最佳配方參數之獲得。並將研發成功的磁性磨料廣泛的應用於不�袗�平面、內外徑、彎曲管、螺旋曲管的內部等零件，期望將可為國內磁力研磨技術帶入另一個嶄新的境界。

The role of magnetic abrasives in Magnetic Abrasive Finishing corresponds to that of the tools used in Machine Tool, which makes magnetic abrasive an important factor during the process of Magnetic Abrasive Finishing. Magnetic abrasives are composite abrasives which must be magnetizable and abrasive. Substances with fine magnetization include Fe, Co, nickel, etc.; varieties of abrasive are Al2O3, SiC, BN, B4C, Diamond Powder and so on. However, the high-priced equipment and special expertise for the making process of magnetic abrasive make the price of import magnetic abrasive stay high.

In order to discuss the surface roughness and material removal weight on the application of stainless steel SUS304 through sintered magnetic abrasive, the study adopts Vacuum Sintering Technology to produce the magnetic abrasives with the combination of Fe and Al2O3, along with the Taguchi Experimental Design for carrying out the sintering experiment so that we could obtain the best parameter of Fe particle, Al2O3 particle, element proportion, pressure (MPa), PVA, temperature and heating time. And finally we analyze the magnetic abrasives by SEM with EDS. The result shows that the self-developed magnetic abrasives through exactly finishing testified can finish the surface of stainless steel SUS304 to Ra 0.018μm. It is good enough to compete with the magnetic abrasives imported from Japan.

The study is to use Vacuum Sintering Technology to develop the magnetic abrasives with higher quality, better wearing resistance , and lower price, that is, the development of magnetic abrasives and the obtainment of the best parameter. The application of successfully developed magnetic abrasives on surface, inside and outside diameter, curve pipe, spiral pipe parts of stainless steel may lead the magnetic abrasive skills of our country to a brand new state.

目 錄

致謝------------------------------------------------------I
中文摘要-------------------------------------------------II
Abstract------------------------------------------------III
目 錄---------------------------------------------------IV
圖目錄--------------------------------------------------VII
表目錄----------------------------------------------------X
第一章 緒論-----------------------------------------------1
1.1研究動機與目的-----------------------------------------1
1.2文獻回顧-----------------------------------------------5
1.3研究方法-----------------------------------------------9
1.4論文架構----------------------------------------------10
第二章 基本原理------------------------------------------11
2.1磁性磨料----------------------------------------------11
2.2磁性磨料製作方法--------------------------------------15
2.2.1單純混合法------------------------------------------15
2.2.2燒結法----------------------------------------------15
2.2.3鋁熱劑法--------------------------------------------16
2.2.4電漿溶融法------------------------------------------16
2.2.5溶膠凝膠法------------------------------------------17
2.2.6機械合金法------------------------------------------17
2.2.7研磨漿研磨法----------------------------------------18
2.2.8不�袗�針研磨法--------------------------------------19
2.2.9真空燒結法------------------------------------------20
第三章 實驗設計與規劃------------------------------------21
3.1田口實驗計畫法----------------------------------------23
3.1.1目標特性的選定--------------------------------------25
3.1.2加工參數設計----------------------------------------25
3.1.3直交表的選定----------------------------------------29
3.1.4訊號/雜訊比-----------------------------------------30
3.1.5 ANOVA變異數分析------------------------------------31
3.1.6驗證實驗--------------------------------------------33
第四章 實驗設備與方法------------------------------------34
4.1實驗設備----------------------------------------------34
4.1.1真空燒結爐------------------------------------------34
4.1.2烘乾爐----------------------------------------------34
4.1.3行星式球磨機----------------------------------------35
4.1.4磨料粒度篩選機--------------------------------------36
4.1.5手動油壓壓床----------------------------------------36
4.1.6磨料壓制模具----------------------------------------37
4.1.7超音波洗淨機----------------------------------------38
4.1.8不鏽鋼研缽------------------------------------------39
4.1.9 CNC四軸綜合加工中心機------------------------------39
4.1.10永久磁鐵拋光機構-----------------------------------40
4.2檢測儀器----------------------------------------------42
4.2.1掃描式電子顯微鏡------------------------------------42
4.2.23D表面輪廓儀----------------------------------------42
4.2.3精密電子天秤----------------------------------------43
4.2.4高斯計----------------------------------------------44
4.3實驗材料----------------------------------------------45
4.3.1工件材料--------------------------------------------45
4.3.2拋光液----------------------------------------------47
4.4實驗方法----------------------------------------------48
4.4.1實驗參數設計----------------------------------------48
4.4.2平面磁力研磨實驗步驟--------------------------------49
4.4.3表面粗糙度之量測------------------------------------50
4.4.4材料移除量之量測------------------------------------51
第五章 實驗結果與討論 -----------------------------------52
5.1磁性磨料燒結結果--------------------------------------52
5.1.1試片一----------------------------------------------52
5.1.2試片二----------------------------------------------53
5.1.3試片三----------------------------------------------55
5.1.4試片四----------------------------------------------56
5.1.5試片五----------------------------------------------57
5.1.6試片六----------------------------------------------58
5.1.7試片七----------------------------------------------59
5.1.8試片八----------------------------------------------61
5.1.9試片九----------------------------------------------62
5.1.10試片十---------------------------------------------63
5.1.11試片十一-------------------------------------------65
5.1.12試片十二-------------------------------------------67
5.1.13試片十三-------------------------------------------68
5.1.14試片十四-------------------------------------------69
5.1.15試片十五-------------------------------------------70
5.1.16試片十六-------------------------------------------72
5.1.17試片十七-------------------------------------------73
5.1.18試片十八-------------------------------------------74
5.1.19試片十九（材料移除量最佳化）-----------------------75
5.1.20試片二十（表面粗糙度最佳化）-----------------------77
5.2田口實驗計劃法的分析----------------------------------78
5.2.1表面粗糙度分析--------------------------------------78
5.2.2材料移除量分析--------------------------------------81
5.3製程參數對磁性磨料特性之影響--------------------------85
5.3.1鐵粉粒度對磁性磨料特性之影響------------------------85
5.3.2氧化鋁粉粒度對磁性磨料之影響------------------------86
5.3.3成分比例對磁性磨料特性之影響------------------------86
5.3.4壓制壓力對磁性磨料特性之影響------------------------87
5.3.5 PVA黏著劑量對磁性磨料特性之影響--------------------87
5.3.6加熱溫度對磁性磨料特性之影響------------------------88
5.3.7加熱時間對磁性磨料特性之影響------------------------88
5.4磁力拋光結果------------------------------------------88
第六章 結論----------------------------------------------92
6.1 結論-------------------------------------------------92
6.2 未來展望---------------------------------------------92
參考文獻-------------------------------------------------94

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