臺灣博碩士論文加值系統

磁力研磨是一種快速且高精度的拋光方法，但在研磨非導磁性材料SUS304不鏽鋼管時，會降低導磁性磨料之磁力，並且，因產生的離心力易將磨料拋離加工區域，進而降低拋光的穩定性。因此，本實驗開發不同的膠體當結合劑，將導磁性磨粒與硬質磨粒拘束於膠體內部，形成導磁性膠體磨料，因膠體磨料具有黏滯性，不但可以將磨粒包覆住，讓磨粒不易飛散，且膠體磨料可以緊密貼附在管壁表面，增加拋光的穩定性。
本研究主要是針對導磁性膠體磨料在SUS304不銹鋼管管內壁的拋光效率，並依不同黏滯性之膠體，且搭配不同加工參數，探討其表面粗糙度及材料移除量的變化。再利用田口實驗法來建立膠體磁力研磨的最佳化參數。為了減少實驗的嘗試次數，先利用ANSYS分析磁極的最佳磁場分佈情形，並設計出適合使用於不鏽鋼管拋光的磁極形狀。依實驗結果顯示，使用黏度較低之水性沙皮膠，採用田口法實驗之最佳化參數，對SUS304不銹鋼管加工30分鐘後，表面粗糙度可由0.636μm Ra降至 0.05μm Ra，表面粗糙度改善率高達92.1%，材料移除量更是高達218.4mg，證實了本文所開發的導磁性膠體磨料結合田口實驗法對不銹鋼管內壁具有優異的拋光效果。

Magnetic abrasive finishing(MAF) is a fast and high-precision polishing method. However, the magnetic force of abrasive particles will drop when polishing non-permeability material such as SUS304 stainless steel tube. Moreover, the abrasive particles will be moved off the surface of machining area due to the centrifugal force of rotation, and reduce the stability of polishing. Therefore, this study developed a series of gels as the bonding material to combine the permeability abrasive particles and hard abrasive particles, then consisted a series of permeability abrasive gels. Generally, those abrasive gels have higher viscosity to dominate the flow property that will constrain uniform motion of the abrasive particles in MAF, and the abrasive gels can be tightly contacted to the wall surface to increase the stability of polishing.
This investigation is focus on the effectiveness of permeability abrasive gels to polish the inner surface of SUS304 stainless steel tube. The changes of surface roughness and removal material volume are studied by utilizing different viscosities of permeability abrasive gels and different machining conditions. Furthermore, a series experiments were conducted to verify the optimum parameters of the MAF machining by using Taguchi method. In this study, the software of ANSYS is adopting to simulate the distribution of magnetic field in order to reduce the experimental counter of try and error. According to the analytical results, we also designed a suitable magnetic mechanism for this study case of polishing non-permeability material. Finally, the testing results using Taguchi method indicated that using water-based Shar-Pei gel of a lower viscosity with optimizing experimental parameters to polish SUS304 stainless steel tube for 30 minutes, the value of surface roughness can be reduced from 0.636μm Ra to 0.05μm Ra, and the amount of removal material is as high as 218.4mg. The roughness improvement rate of permeability abrasive gels is roughly 92.1%, it demonstrated that permeability abrasive gels of our developmental material combined with Taguchi method have excellent polishing performance for stainless steel tube.

中文摘要 i
英文摘要 ii
誌謝 iii
目錄 iv
表目錄 vi
圖目錄 vii
符號說明 ix
第一章 緒論 1
1.1 前言 1
1.2 研究動機與目的 3
1.3 文獻回顧 5
1.4 論文架構 10
第二章 實驗原理 11
2.1 膠體磁力研磨加工之基本原理 11
2.2 膠體 14
2.2.1膠體之黏滯性 14
2.3 表面粗糙度 15
2.4田口式品質穩健設計法 18
2.4.1田口式實驗法與傳統實驗之差異 19
2.4.2品質特性 22
第三章 實驗設備與方法 24
3.1 實驗設備 24
3.2 實驗材料 33
3.3 實驗方法 36
3.3.1 探討各別實驗因子對研磨結果之影響 36
3.3.2 田口法實驗 38
3.3.3 探討不同形狀之磁極對磁場的影響 39
3.3.4 不同磁極形狀對表面粗糙度之探討 40
第四章 結果與討論 41
4.1 實驗結果 41
4.1.1 有無添加磨料對研磨結果的影響 41
4.1.2 不同膠體對研磨結果的影響 42
4.1.3 不同碳化矽比例對研磨結果的影響 45
4.1.4 不同鋼砂比例對研磨結果的影響 47
4.1.5 不同碳化矽粒徑對研磨結果的影響 49
4.1.6 不同鋼砂粒徑對研磨結果的影響 52
4.1.7 不同迴轉速度對研磨結果的影響 53
4.1.8 不同往復速度對研磨結果的影響 55
4.1.9 不同電流大小對研磨結果的影響 57
4.2 田口法實驗 59
4.2.1 田口法實驗結果(表面粗糙度) 59
4.2.1.1 變異數分析(表面粗糙度) 61
4.2.1.2田口法實驗之最佳參數驗證結果(表面粗糙度) 62
4.2.2 田口法實驗結果(材料移除量) 64
4.2.2.1 變異數分析(材料移除量) 66
4.2.2.2 田口法實驗之最佳參數驗證結果(材料移除量) 67
4.3 探討不同形狀之磁極對磁場的影響 69
4.4 不同磁極形狀對表面粗糙度之探討 71
4.4.1 圓弧齒狀形磁極對最佳化參數之探討 71
4.4.2 圓弧齒狀形磁極對矽膠膠體之探討 72
4.5 試片表面研拋之研拋結果 74
第五章 結論 75
參考文獻 77
簡 歷 84

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