臺灣博碩士論文加值系統

隨著各產業的快速起飛及其產品的需求量持續提升，多數相關組件必須使用工具機製造，為了因應全球的競爭趨勢，加工製造勢必講求快速而有效率，使得工具機的需求量日益增加。由於高速主軸系統亦可說是工具機的心臟，高品質工具機需搭備高剛性及高性能之主軸，因高剛性主軸具備了良好的切削阻抗與切削穩定性的保持及滿足精密加工等須求，將有助於生產速率的提昇並有效地增進其附加價值。因此，主軸系統剛性提昇之設計與製造，以提高切削加工之精密度與穩定性，乃為精密主軸相關業者當前努力的方向與課題。
本文結合主軸設計輔助軟體，並搭配實務性的實驗驗證，發展高速主軸剛性提昇之設計技術建構。首先，檢視主軸剛性影響因子，試著去確立主軸剛性的主要影響因子，計有滾珠接觸角、軸承跨距、軸承預壓及軸承排列配置形式等設計參數並建立全因子組合。接著，使用主軸設計輔助軟體建構主軸模型，並求出每一設計參數組合之主軸剛性，同時估算熱源並以有限元素法從事主軸模態與軸承溫升模擬。以主軸剛性為目標函數，受制於軸承容許溫升的拘束條件要求，求取最佳或較佳主軸剛性的設計參數組合。然後依照所求得之最佳或較佳設計參數建構實體主軸，同時針對主軸系統執行靜剛性、動態特性(迴轉精度)及軸承運轉溫升監測等實驗。結果顯示，實驗與模擬有著相同的趨勢，影響主軸最主要因子為軸承接觸角、軸承跨距與排列型式；雖然軸承接觸角越大與軸承跨距越小其主軸剛性越好，但是運轉時產生的溫度會比原來的高；軸承排列形式為前後軸承數各為兩個為較佳之排列配置。

As industries take off rapidly and the product demand amounts growing up continuously, most of the related parts and components in a product rely on machine-tool equipment to produce eagerly. In response to global competition, the machining and manufacturing should all be fast, effective and efficient, thus the needs of machine tools are augmented naturally day by day. A high-speed spindle system is the heart of a machine-tool and a high-quality machine-tool is always coupled with a spindle system that has high stiffness and better performance. Since high stiffness spindle system may provide the better abilities to withstand cutting-loading and to keep cutting stability that may satisfy the precision machining requirements, which can help production rate promotion and increase added value effectively. Therefore, the design and manufacturing of a spindle system with stiffness promotion for better machining precision and stability is one issue that the precision spindle makers have to deal with at the present time.
A spindle design-aided software and a practical execution of experimental verification are combined together to develop a design technique for a high-speed spindle stiffness promotion construction. First of all, check all possible influencing factors on spindle stiffness and try to ascertain those main influencing factors or design parameters such as span of bearings, ball bearing contact angle, bearing preload, and bearing arrangement and configuration type in a spindle system, etc. Next, the spindle design-aided software is utilized to construct the geometrical model of a spindle system and to determine the spindle stiffness for each combination of design parameters. At the same time, the FEM is applied to simulate the modal analysis and temperature rise in bearings while heat sources generated in a spindle system are estimated preliminarily. By selecting spindle stiffness as an objective function which is subjecting to a constraint of bearing allowable temperature rise and the better design parameters combinations can thus be determined for expected spindle stiffness. A solid spindle system was fabricated according to this better design parameter combination. Finally, experiments were carried out on these spindle systems for static stiffness measurements, and monitoring on dynamic characteristics (run-out) and temperature rise in the bearings during the run-in tests. The results obtained from the simulations exhibits the similar trends to those of experiments. The major factors affecting the spindle stiffness are ball bearing contact angle, span of bearings, and bearing arrangement and configuration type. The greater is the contact angle of bearing and the smaller is the bearing span, the higher is the spindle stiffness which the higher temperature rise accompanied in operations unfortunately. For the bearing arrangement and configuration type, a better arrangement is with two bearings at the front-end and two at the rear in this improved spindle system.

中文摘要………………………………………………………………i
Abstract………………………………………………………………ii
致謝 ………………………………………………………………iv
目錄 ………………………………………………………………v
表目錄 ………………………………………………………………vii
圖目錄 ………………………………………………………………viii
第一章 前言…………………………………………………………1
1.1 研究背景……………………………………………………1
1.2 研究動機與目的……………………………………………2
1.3 文獻回顧……………………………………………………4
1.4 論文架構……………………………………………………9
第二章 理論基礎……………………………………………………10
2.1 結構共振理論………………………………………………10
2.2 快速傅立葉轉換……………………………………………13
2.3 軸承搭配型式與預壓………………………………………14
2.4 熱傳遞..……………………………………………………18
第三章 數值模擬與實驗方法..............................20
3.1 數值模擬與計算軟體工具...………………...........21
3.1.1 數值模態與熱傳……………………...........23
3.1.2 主軸設計輔助軟體…………………….........25
3.2 實驗模態分析……………………………………........26
3.2.1 實驗儀器設備.………………................27
3.2.2 實驗方法與步驟……………………...........31
3.3 溫度監測實驗........………………………………....37
3.3.1 實驗儀器設備…………………...............37
3.3.2 實驗方法與步驟……………………...........38
3.4 迴轉精度實驗………………………………............41
3.4.1 實驗儀器設備…………………….............41
3.4.2 實驗方法與步驟……………………...........43
第四章 主軸改良設計....................................46
4.1 影響主軸剛性主要參數探討........................49
4.2 主軸剛性提升之設計..............................53
第五章 結果與討論......................................59
5.1 主軸改良前......................................59
5.1.1 實驗模態分析.............................59
5.1.2 溫度監測實驗.............................65
5.2 主軸改良後......................................67
5.2.1 實驗模態分析.............................67
5.2.2 溫度監測實驗.............................71
5.2.3 迴轉精度實驗.............................72
5.3 改良前後之比較..................................73
第六章 結論與建議………………………………………........74
參考文獻………………………………………………………………76
附錄 ………………………………………………………………79
Extended Abstract …………………………………………84
作者簡歷………………………………………………………………87

[1]Y. Altintas and Y. Cao, 2005, "Virtual Design and Optimization of Machine Tool Spindles", CIRP Annals - Manufacturing Technology, Vol.54, pp.379-382.
[2]Y.S. Chen, C.C. Chiu1, Y.D. Cheng, 2010, "Influences of operational conditions and geometric parameters on the stiffness of aerostatic journal bearings", Precision Engineering, Vol.34, pp.722-734.
[3]Yuan Kang, Chih-Ching Huang, Chorng-Shyan Lin, Ping-Chen Shen, Yeon-Pun Chang, 2006, "Stiffness determination of angular-contact ball bearings", Tribology International, Vol.39, pp.461-469.
[4]Hongqi Li, Yung C. Shin, 2004, "Analysis of bearing configuration effects on high speed spindles using an integrated dynamic thermo-mechanical spindle model", International Journal of Machine Tools & Manufacture, Vol.44, pp.347-364.
[5]M. A. Alfares and A. A. Elsharkawy, 2003, "Effects of axial preloading of angular contact ball bearings on the dynamics of a grinding machine spindle system", J. Mater. Process. Technol, Vol.136, pp.48-59.
[6]J.K. Choi and D. G. Lee, 1997, "Characteristics of a spindle bearing system with a gear located on the bearing span", Tools Manufact, Vol.37, pp.171-181.
[7]L. Brzeski , Z. Kazimierski , T. Lech, 1999, "Experimental investigations of precision spindles equipped with high stiffness gas journal bearings", Precision Engineering, Vol.23, pp.155-163.
[8]Jenq-Shyong Chen and Kwan-Wen Chen, 2005, "Bearing load analysis and control of a motorized high speed spindle", International Journal of Machine Tools & Manufacture, Vol.45, pp.1487-1493.
[9]Matti Rantatalo , Jan-Olov Aidanpaa, Bo Goransson, Peter Norman, 2007, "Milling machine spindle analysis using FEM and non-contact spindle excitation and response measurement", International Journal of Machine Tools & Manufacture, Vol.47, pp.1034-1045.
[10]Chi-Wei Lin, Jay F. Tu, Joe Kamman, 2003, "An integrated thermo-mechanical-dynamic model to characterize motorized machine tool spindles during very high speed rotation", International Journal of Machine Tools & Manufacture, Vol.43, pp.1035-1050.
[11]S.A. Spiewak and T. Nickel, 2001, "Vibration based preload estimation in machine tool spindles", International Journal of Machine Tools & Manufacture, Vol.44, pp.567-588.
[12]S. M. Kim, K. J. Lee, S. K. Lee, 2002, "Effect of bearing support structure on the high-speed spindle bearing compliance", Int. J. Mach. Tools Manufact, Vol.42, pp.365-373.
[13]S. Yoshimoto, T. Kume, T. shitara, 1998, "Axial load capacity of water lubricated hydrostatic conical bearings with spiral grooves for high speed spindles", Tribology international, Vol.31 No.6, pp.331-338.
[14]Cheng-Hsien Wu. and Yu-Tai Kung, 2005, "A parametric study on oil/air lubrication of a high-speed spindle", Precision Engineering, Vol.29, pp.162-167.
[15]G.D. Hagiu and M.D. Gafitanu, 1997, "Dynamic characteristics of high speed angular contact ball bearings", Wear, Vol.211, pp.22-29.
[16]A. Slocum, M. Basaran, R. Cortesi , A. J. Hart, 2003, "Linear motion carriage with aerostatic bearing preloading by inclined iron core linear electric motor", Precision Engineering, Vol.27, pp.382-394.
[17]Vincent Gagnol, Thien-Phu Le and Pascal Ray, 2011, "Modal identification of spindle-tool unit in high-speed machining", Mechanical Systems and Signal Processing, Vol.25, pp.2388-2398.
[18]S.A. Spiewak and T. Nickel, 2001, "Vibration based preload estimation in machine tool spindles", International Journal of Machine Tools & Manufacture, Vol.44, pp.567-588.
[19]Osamu Maeda, Yuzhong Cao and Yusuf Altintas, 2005, "Expert spindle design system", International Journal of Machine Tools & Manufacture, Vol.45, pp.537-548.
[20]E. Budak, A. Erturk and H.N. Ozguven, 2006, A Modeling Approach for Analysis and Improvement of Spindle-Holder-Tool Assembly Dynamics, CIRP Annals - Manufacturing Technology, Vol.55, pp.369-372.
[21]S. Vafaei, H. Rahnejat, and R. Aini, 2002, Vibration Monitoring of High Speed Spindles Using Spectral Analysis Techniques, International Journal of Machine Tools & Manufacture, vol.42, pp1223-1234.
[22]Zhao Haitao, Yang Jianguo, Shen Jinhua, 2007, Simulation of thermal behavior of a CNC machine tool spindle, International Journal of Machine Tools & Manufacture, Vol.47, pp.1003-1010.
[23]Jin Kyung Choi, Dai Gil Lee, 1998, Thermal characteristics of the spindle bearing system with a gear located on the bearing span, Machine Tools & Manufacture, Vol.38, pp.1017-1030.
[24]繆武良，2006，工具機主軸設計與彈簧預壓影響之研究，逢甲大學材料與製造工程系碩士論文。
[25]單寶峰、王海強、李景春，2010，高速旋轉主軸軸承干涉配合的影響因素分析，機械製造，第48卷，第556期。
[26]汪育群、紀華偉，2005，主軸軸向與徑向預壓探討，第十三屆中華民國振動與噪音工程學術研討會，pp.484-489。
[27]楊明亞，楊濤、湯本金、周永良、阴紅，2006，ANSYS在數控機床模態分析中的應用，中國製造業信息化，第38卷，第17期，第40-43頁。
[28]趙金生、紀華偉，2002，主軸系統靜剛性試驗與分析，第五屆全國機構與機器設計學術研討會。
[29]王瑞昌，2010，“內藏式主軸之共振現象的理論探討與實際應用”，國立清華大學碩士論文。
[30]楊明亞、楊濤、湯本金、周永良、陰紅，2006，ANSYS在數控機床模態分析中的應用，中國製造業資訊化，第35卷，第17期。
[31]吳玉厚，劉小文，張珂，李頌華，王賀，2010，170SD30全陶瓷電主軸有限元分析及其振動性能測試，瀋陽建築大學學報(自然科學版) ，第26卷，第4期。
[32]熊萬里、黃紅武、張俊輝、鄧新春，2004，高速精密電主軸動態熱態特性的研究發展，振動工程學報，第十七卷增刊，第61-64頁。