臺灣博碩士論文加值系統

本文為減少因配方導致開發砂輪成本提高，設計出一套新的測試方式希望能使得配方設定時間縮短；砂輪主要由磨料、結合劑、組織三大要素所構成，而砂條與砂輪結構相同幾何形狀不同，因此本文以砂輪之製程來製作CBN樹脂砂條。而以往測試砂輪表面組織往往經由破片來觀察研磨後砂輪表面情形，但此方式卻無法仔細觀察磨料與結合劑在經研磨後產生之微結構變化，因此本文設計出可乘載砂條之載台，而載台能夠置入電子顯微鏡(SEM)腔體進行微結構觀察，在設計出能配合載台及並且有研磨行為之治具，使其在研磨前後分段觀察砂條中磨粒之結構變化，與工件品質進行交叉比對。因CBN樹脂砂輪中之樹脂常因為研磨時產生的熱而導致壽命驟減及工件品質較差，因此本文所設定之固態磨料中混入(0、1、5 wt%)具有潤滑效果及導熱效果較佳之微米石墨，對硬度HRC 60~61之SKD11鋼材以研磨方式，對磨料研磨前後進行觀察。希望能改善CBN樹脂砂輪之壽命及提升工件品質。經由實驗結果顯示：添加5wt %可達高之材料移除量，而1wt %可得到較佳之重量比與工件表面品質高，並且磨耗量最低，可得知含石墨量1wt%之CBN樹脂砂條可達到移除量高、砂條壽命低、工件品質佳之砂條。

The purpose of this study is design a new sand stick to decrease compounding recipe times. We all know, Wheel structure of three elements is abrasives, binders and pores. Sand stick and wheel have same structure but different geometric shapes, so this paper manufacturing CBN resin sand stick from wheel process. Previous test wheel surface are often observed by the situation after grinding wheel surface, but this method can’t carefully observe the micro-structural variations in the abrasives and binders after grinding, so this paper design platform can carry out of the sand stick, The platform can put in scanning electron microscope (SEM) cavity, and easy observe the micro-structural variations structure on sand stick worn surface. Actually, CBN resin wheel due to heat generated decrease grinding life and caused poor quality on grinding surface. This study will added (0,1,5 wt%) has better lubricating and thermal effects micron graphite in sand stick, then, grinding hardness of HRC 60 ~ 61 of SKD11 steel. The experimental results showed that: adding 5wt% micron graphite can improve material removed rate, 1wt% micron graphite can obtain better surface quality on workpiece, high grinding ratio, and minimum amount of wear.

摘 要 2
ABSTRACT 3
誌謝 4
目錄 6
表目錄 8
圖目錄 9
第一章 導論 12
1.1研究動機 12
1.2 研究目的及方法 23
1.3論文架構 24
第二章 磨削理論 26
2.1 研磨作用 26
2.2砂輪磨損情形 27
2.3 磨削力與磨削功率 28
2.4 砂輪與工件接觸弧長 29
2.5磨削溫度 30
2.6 未變形切屑厚度 31
2.7 磨耗比(GRINDING RATIO) 31
2.8 比磨削能(SPECIFIC GRINDING ENERGY) 32
2.9 磨料晶粒之拉伸強度 32
第三章 樹脂CBN砂條載台及治具 33
3.1載台設計&;砂條安置流程 33
3.2 治具及配合方式 35
3.3 樹脂CBN砂條載台及治具特色 37
第四章 實驗規劃與設備 38
4.1 實驗設備 38
4.2實驗材料及耗材 44
4.3 實驗方法與步驟 50
第五章 實驗結果分析與討論 53
5.1 砂條硬度分析 53
5.2 抗折強度與破斷面觀察 56
5.3 砂條對於工件材料移除量之影響 60
5.4 砂條壽命及工件表面粗糙度 62
5.5 砂條表面研磨型態 66
第六章 結論 76
第七章 未來展望 78
參考文獻 79










表目錄
表2-1結合劑之比較 28
表4-1 精密平面磨床規格 39
表4-2 砂條參數 44
表4-3 SKD11工具鋼化學成分 45
表4-4環氧樹脂黏著劑 46
表4-5 紅銅化學成分 47
表4-6 研磨參數表 52
表5-1 砂條硬度測試表 54
表5-2 砂條抗折強度測試表 57
表5-3-1磨削工件之材料移除量 61





















圖目錄
圖1-1 石墨晶體層狀結構中原子的中心位置[48] 21
圖2-1 磨粒與結合劑 26
圖2-2 砂輪主要三種不同的磨損情形 27
圖2-3 磨削力與磨削功率 28
圖2-4 砂輪與工件之接觸 29
圖2-5 磨削溫度 30
圖2-6 未變形切屑厚度 31
圖3-1載台樣式 34
圖3-2 載台內部均勻塗上環氧樹脂 34
圖3-3 將砂條放置於載台上 34
圖3-4 置於加熱板上 34
圖3-5 將砂條及載台加壓 34
圖3-6 治具本體 35
圖3-7 治具結合方式 36
圖3-8 治具爆炸圖 36
圖3-9 治具鎖固方式 37
圖3-10 砂條載台放入位置 37
圖4-1 精密平面磨床 38
圖4-2 砂輪動平衡校正儀 39
圖4-3 掃描式電子顯微鏡(SEM) 40
圖4-4 硬度測試機 40
圖4-5 泓達萬能試驗機 41
圖4-6 試片示意圖 41
圖4-7 表面粗糙度儀 42
圖4-8 微量天平 42
圖4-9 超音波洗淨機 43
圖4-10平板式快速加熱器 43
圖4-11 CBN樹脂砂條圖 44
圖4-12工件材料SKD11工具鋼實體圖 45
圖4-13 DP-420環氧樹脂結合劑 46
圖4-14 紅銅修整塊 47
圖4-15 SiC修整塊 48
圖4-16 Al2O3白色修整塊 48
圖4-17 三種修整塊修整砂條時間對照圖 49
圖4-18 治具架設圖 51
圖4-19 實驗流程圖 51
圖5-1 砂條測試圖 53
圖5-2 未添加石墨硬度與集中度圖 55
圖5-3添加石墨1 wt%硬度與集中度圖 55
圖5-4添加石墨5 wt%硬度與集中度圖 56
圖5-5 砂條抗折測試圖 57
圖5-6 集中度50石墨添加量對於抗折強度影響 58
圖5-7 集中度75石墨添加量對於抗折強度影響 59
圖5-8 集中度100石墨添加量對於抗折強度影響 59
圖5-9 破斷面觀察圖 60
圖5-10 集中度對於材料去除量之影響 61
圖5-11 集中度對於工件品質之影響 62
圖5-12 石墨添加量對於重量比之影響 63
圖5-13 石墨添加量對材料移除量之影響 64
圖5-14 石墨添加量對於砂條磨耗量之影響 65
圖5-15 石墨添加量對於工件品質之影響 66
圖5-16 削正、銳後之SEM圖 67
圖5-17 研磨前(SEM30x) 67
圖5-18 研磨後(SEM30x) 67
圖5-19 研磨前(SEM150x) 67
圖5-20 研磨後(SEM150x) 67
圖5-21磨粒破碎(SEM 500x) 68
圖5-22磨粒自銳(SEM 700x) 68
圖5-23 0wt%石墨(SEM 100x) 69
圖5-24 1wt%石墨(SEM 100x) 70
圖5-25 5wt %石墨(SEM 100x) 71
圖5-26 未添加石墨之磨粒碎裂情形(SEM 500x) 72
圖5-27添加石墨之磨粒碎裂情形(SEM 1kx、700x) 72
圖5-28砂條中磨粒碎裂情形(SEM 150x) 73
圖5-29砂條中磨粒破碎(SEM 500x) 74
圖5-30砂條中磨粒脫落不完全(SEM 500x) 74
圖5-31砂條中磨粒磨耗過程(SEM 500x) 75

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