臺灣博碩士論文加值系統

樹脂砂輪的構造主要由磨料、結合劑、組織所組成，由於砂輪與砂條之結構相同，因此本實驗使用砂輪之製程來製作樹脂CBN砂條，利用砂條幾何形狀不同之緣故來節省製作時間、實驗經費以及能夠觀察砂條表面微結構。以往在觀察砂輪表面組織往往經由破片來觀察研磨後砂輪表面情形，此方式卻無法仔細觀察到磨料與結合劑在經過研磨後產生之微結構變化，因此本文改良一可承載砂條之載台，而載台之體積大小能夠置入電子顯微鏡(SEM)腔體內進行微結構觀察，接著設計一可與載台做嵌合動作且能夠固鎖於磨床心軸上進行研磨作業之治具，此治具及載台能夠幫助本研究觀察砂條研磨前後之微結構變化。本實驗之研磨材料為硬度HRC 60 ~ 61之DC53鋼材，設定之砂條配方為添加不同重量百分比之碳黑(0、1、5)wt% 和銅(0、1、5)wt%以及兩種不同型號之磨粒，分別為一般CBN磨粒BBN-4及有鍍鎳CBN磨粒BBN-4-60NS。經過研磨實驗後發現碳黑添加量為1wt%時能對砂條磨耗量造成較佳之影響，而碳黑添加量5wt%時工件表面粗糙度最佳。而銅對砂條具有潤滑之效果，所以在有添加銅之砂條上同樣發現了砂條磨耗量降低之趨勢。

Grinding wheel comprises abrasive、bond and structure. In this study, it was used in the producing process of resin-bonded CBN specimen because they have the same ingredients. Their different geometric shapes, however, make it possible to reduce the experimental cost and the producing time and to observe the surface of microstructure of CBN specimens. In the past, grind wheel’s microstructure was observed by the fragment after grinding. Which failed to provide a comprehensive observation about the variation on bond and abrasive. To solve the above-mentioned problem, a carrier is modified to place in scanning electric microscope (SEM) for observation. Then, a holder which could be locked to the grinder spindle and allow the carriers to attach to it for grinding process is designed. Such equipment helps to observe the microstructure of CBN specimens after and before grinding. In this study, the workpiece is DC53 steel which undergoes thermal treatment to HRC 60～61. And the resin-bonded CBN specimens containing different amount of carbon black (0, 1, 5) wt% and Cu (0, 5) wt% are used, along with two species of abrasive, the CBN abrasive BBN-4 and the BBN-4-60NS which is coating Nickel on BBN-4. It is found out that the CBN specimen has lower abrasion when it contains 1wt% carbon black filler, and the CBN specimen contains 5wt% carbon black filler makes the best surface roughness of DC53. And due to the lubricating of Cu, the CBN specimen’s abrasion is decreased by Cu.

誌謝 I
摘 要 III
ABSTRACT IV
目錄 V
表目錄 VIII
圖目錄 IX
第一章 緒論 1
1.1 前言 1
1.2 研究目的及方法 11
1.3 論文架構 12
第二章 磨削理論 14
2.1 研磨作用 14
2.2 砂輪磨損情形 15
2.3 磨削力與磨削功率 16
2.4 砂輪與工件接觸弧長 17
2.5 磨削溫度 18
2.6 未變形切屑厚度 19
2.7 磨削比 20
2.8 比磨削能 21
2.9 磨粒拉伸強度 21
2.10 工件表面粗糙度 21
第三章 實驗規劃與設備 23
3.1 實驗設備 23
3.2 實驗材料及耗材 30
3.3 實驗方法與步驟 34
第四章 樹脂CBN砂條載台及治具 38
4.1 載台設計及砂條黏結於載台上流程 38
4.2 治具及載台配合方式 40
4.3 樹脂CBN砂條載台及治具特色 42
第五章 結果分析與討論 45
5.1 砂條抗折強度分析 45
5.1.1 磨粒對砂條抗折強度之影響 47
5.1.2 銅填充材料對砂條抗折強度之影響 49
5.1.3 碳黑填充材料對砂條抗折強度之影響 50
5.2 磨削實驗結果與討論 52
5.2.1 磨粒對砂條磨耗量之影響 52
5.2.2 填充材料對砂條磨耗量之影響 54
5.2.3 磨粒對材料移除量之影響 55
5.2.4 填充材料對材料移除量之影響 57
5.2.5 工件表面粗糙度及形貌 58
5.2.6 不同進給量及磨削比之結果 62
5.3 砂條表面型態觀察 71
第六章 結論 81
第七章 未來展望 83
參考文獻 84

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