臺灣博碩士論文加值系統

球形端銑刀(ball end mill)為曲面精切削加工中最常用的切削刀具，曲面精切削時球形端銑刀的切削量不大，對於球形端銑刀切削加工完成後工件表面的品質要求非常高。由於球形端銑刀的刀刃形狀為圓弧形，導致切削時，會在切削路徑間（pitch between two cutting paths）形成扇形高度(Scallop height)，並且會因球形端銑刀刀刃在切削時之旋轉和移動的效應而形成在切削進給間（feed between two cutting teeth）之方向產生切削殘留(Cutting Remainder)。此二種切削殘留是影響精切削完成後形成工件表面粗糙度的主要因素。
切削進給方向之切削殘留形成的原因比扇形高度來得複雜，而且較難使用幾何圖形解析方式來求得。本文先建立球刀切削點運動軌跡之數學方程式，再使用牛頓拉佛森疊代法解出刀刃切削點之運動路徑時間差，進而代入球刀切削點運動方程式以數值方法求得球刀刀刃加工運動路徑之交點，找出在不同切入角度相位差及不同刀具傾斜角之因素下切削殘留(Cutting Remainder)最高點之值及位置。再配合"Z方向搜尋法(Z-map)"的運算方式，模擬出球形端銑刀在不同的切削條件下所形成的切削殘留3D圖。針對不同刀具半徑以及不同之每刃進給和刀具加工之路徑間距找出最佳之進給速率的組合以兼顧表面粗糙度和加工效率。以及針對刀刃形狀的的改進研究。

The ball end mill is a general cutter at the working of surface finishing cutting. At finishing cutting the cutter loading is small, so for the surface roughness demand is high grade. But the ball end mill is a arc cutter so that generate "scallop height" on pitch between two cutting path and feed between two cutting teeth generate "feed direction cutting remainder " because the ball end mill rotate and moving. It is main factor become surface roughness
The "feed direction cutting remainder" is more complex then the "scallop height" at generate cause. And difficult to get the cutting remainder height use geometrical analysis. This thesis we build the "cutting path mathematics model", use "Newton''s Method" solution for the time different value, and to find the cutting remainder position and the highest value, use "Z-map" method to simulation the cutting remainder 3D figure at difference cutting condition. And to decision the best feed-rate at finishing cutting of difference cutting condition. We can get a work of smooth surface and efficiency. And to modify the cutter shape of the ball end mill is our target.

第一章 緒論…………………………………………………..........1
1-1 研究動機與目的………………………………………………1
1-2 文獻回顧………………………………………………………2
1-2-1 切削殘留…………………………………………………….2
1-2-2 切削條件規劃……………………………………………….4
第二章 切削殘留……………………………………………...6
2-1 銑削的表面性質………………………………………………6
2-2 表面切削殘留的種類…………………………………………8
2-3 扇形高度殘留及其發生之原因……………………………...10
2-4 進給方向切削殘留及其發生之原因………………………...12
2-5 銑削加工切削條件的選擇…………………………………..18
2-6球形端銑刀的切削速度、進給速率及轉速之關係………...20
第三章 球刀刀刃數學模型及電腦模擬……………………23
3-1刀刃運動軌跡數學模式之推導建立………………………...23
3-1-1座標的定義………………………………………………..23
3-1-2球刀之平面運動方程式………………………………….25
3-1-3 運動軌跡之交點…………………………………………27
3-1-4 數值模擬的方法及模擬結果……………………………32
3-2 球刀切削殘留之最高點……………………………………42
3-2-1.運動方程式……………………………………………44
3-2-2.數值模擬方法流程……………………………………44
3-2-3.數值模擬數據及實驗數據之比對……………………45
3-2-4 Z方向搜尋法及3D模擬圖…………………………….46
3-3 最大切削殘留高度和最佳進給量之關係…………………..60
3-4.球刀不同切削角度之影響…………………………………..62
3-4-1.運動方程式……………………………………………........62
3-4-2.數值模擬流程圖………………………………………........64
3-4-3.數值模擬結果及3D模擬圖與實際切削之比較………........67
3-5.球刀不同刀具傾斜切削角度之影響………………………...73
3-5-1.運動方程式……………………………………………........73
3-5-2.數值模擬流程圖及數值模擬結果……………………........75
3-5-3.3D模擬圖及實驗照片…………………………………........78
第四章. 球形端銑刀靜點部分刀刃刃形之修正
4-1.曲面切削時所使用之球形端銑刀………………………….84
4-2 球形端銑刀靜點部分刀刃刃形修正原因………………….93
4-3 靜點部分刀刃double-V-cut形狀之球形端銑刀…………......95
第五章 結論及討論………………………………………….........99
5-1.結論與討論…………………………………………………..99
5-2.未來研究方向………………………………………………..101
參考文獻……………………………………………………...........102

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[26] 專利號碼：jp1228711之刃形修正球形端銑刀
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[28] 專利號碼：jp2303707之刃形修正球形端銑刀
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[30] 專利號碼：jp5138425之刃形修正球形端銑刀
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