臺灣博碩士論文加值系統

本研究係利用雕模放電加工機對鈦合金(Titanium Alloy, Ti6Al4V)進行放電加工，實驗主要目的在分析放電加工參數對鈦合金放電加工特性的影響。實驗中為了有效地了解放電加工主要參數對鈦合金放電加工的影響，其中針對材料去除率、電極消耗率、相對電極消耗率及表面粗糙度等加工後特性加以討論。鈦合金進行放電加工時，材料去除率會隨放電電流和脈衝時間的增加而逐漸增大，脈衝時間大約在400s時達到最大值，然後隨脈衝時間的繼續增加卻反而有呈現下降的趨勢。而電極消耗率會隨放電電流的增加有逐漸變大的現象；並且在各放電電流的加工條件下，會隨著脈衝時間的增加而逐漸降低。又加工表面的粗糙度隨著放電電流的增加而變粗糙，且隨著脈衝時間的增加而呈現下降的趨勢。
另研究實驗的部分將輔以田口實驗計劃法(Taguchi methodology)之直交表規劃實驗，藉由統計方法中之變異數分析及貢獻度，探討鈦合金放電加工中放電電流(IP)、脈衝時間(on)、放電間隙(Gap)及無負荷電壓(V)等四個主要的加工參數對鈦合金放電加工特性的影響與關係。並評估放電加工參數對加工特性之實驗觀察值產生影響的顯著程度，以及求出各加工特性之最佳加工參數組合水準值，以提供工業界及相關研究工作者參考。

In this study, Titanium Alloy (Ti6Al4V) was machined by electrical discharge machining (EDM) to investigate the effects of machining parameters on machining characteristics. Therefore, parts of experiment were conducted with orthogonal arrays of Taguchi method for economically to explore the machining parameters on machining characteristics such as material removal rate (MRR), electrode wear rate (EWR), relative electrode wear ratio (REWR) and surface roughness (SR). Besides, through analysis of variance (ANOVA) and F test of signal to noise (S/N) ratio, the effects of machining parameters such as peak current (IP), pulse duration (on), no load voltage (V), and discharge gap (Gap) on machining characteristics were determined. From this investigation, the relations between machining characteristics and machining parameters of titanium alloy via EDM’s parameters were established. Furthermore, the significant degree of each parameters affected the machining characteristics were explored, and the optimal combination levels of the machining parameters on MRR, EWR, REWR and surface roughness was determined. Moreover, the experimental results could be applied in industrial applications and academic researches.

目錄
中文摘要.................................................................................................i
英文摘要...............................................................................................iii
目錄...................................................................................................iv
圖目錄..................................................................................................vi
表目錄................................................................................................viii
第一章 緒論...............................................................................................1
1-1研究動機..............................................................................................1
1-2研究目的..............................................................................................2
第二章 文獻回顧...........................................................................................4
2-1鈦合金介紹.............................................................................................4
2-2放電加工原理簡介........................................................................................5
2-3放電加工參數...........................................................................................8
2-4放電加工特性...........................................................................................9
2-5放電極性對積碳影響......................................................................................9
2-6放電加工積碳影響.......................................................................................17
2-7放電加工表面缺陷.......................................................................................18
第三章 實驗方法與步驟.....................................................................................25
3-1實驗材料.............................................................................................25
3-2實驗設備.............................................................................................27
3-3實驗加工條件..........................................................................................31
3-4田口實驗計畫法的步驟...................................................................................31
第四章 結果與討論.........................................................................................36
4-1材料去除率............................................................................................36
4-2電極消耗率............................................................................................37
4-3表面粗糙度............................................................................................39
4-4表面放電坑…………….......................................................................................41
4-5田口實驗計畫法的分析...................................................................................42
4-5-1材料去除率之分析.....................................................................................43
4-5-2電極消耗率之分析.....................................................................................44
4-5-3相對電極消耗率比的分析................................................................................46
4-5-4表面粗糙度之分析.....................................................................................47
第五章 結論..............................................................................................49
參考文獻................................................................................................51
圖目錄
圖2-1放電加工機構示意圖[27] ...............................................................................7
圖2-2放電加工之材料移除過程示意圖[13] .......................................................................7
圖2-3淺坑與痘瘡形成之示意圖[77] ...........................................................................19
圖2-4 S45C 其變質層的硬度自表層隨深度而向內變化之情[81] .......................................................23
圖2-5放電加工後表面殘留應力示意圖...........................................................................24
圖2-6 SKD11 放電加工後殘留應力分佈圖[81] ...................................................................24
圖3-1 Ti-6Al-4V鈦合金之微結構，層狀為α相,大顆粒為β相; X500...................................................25
圖3-2億耀（YAMJET-505型ZNC）放電加工機圖...................................................................27
圖3-3放電加工裝置示意圖...................................................................................27
圖3-4超音波洗淨機圖.......................................................................................28
圖3-5精密電子圖..........................................................................................29
圖3-6表面粗度儀圖........................................................................................30
圖3-7掃描式電子顯微鏡(JSM-6360 LV型)圖.....................................................................30
圖4-1不同放電電流與脈衝時間對材料去除率關係...................................................................37
圖4-2不同放電電流與脈衝時間對電極消耗率關係...................................................................37
圖4-3不同放電電流與脈衝時間對工件表面粗糙度關係................................................................39
圖4-4不同放電電流與脈衝時間對放電坑直徑之關係..................................................................40
圖4-5放電加工鈦合金表面IP 20A, on:800 s(a)放電加工之表面, (b)放電加工縱剖面及裂縫..............................41
圖4-6放電加工鈦合金MRR之主反應圖............................................................................44
圖4-7放電加工鈦合金EWR之主反應圖............................................................................45
圖4-8放電加工鈦合金REWR之主反應圖...........................................................................46
圖4-9放電加工鈦合金Ra之主反應圖.............................................................................48
表3-1紅銅棒的物理性質.....................................................................................26
表目錄
表3-2放電加工的實驗條件...................................................................................31
表3-3 L9直交表..........................................................................................32
表4-1放電加工鈦合金之田口分析S/N比之結果.....................................................................42
表4-2放電加工鈦合金MRR之單因子變異數分析.....................................................................44
表4-3放電加工鈦合金EWR之單因子變異數分析.....................................................................45
表4-4放電加工鈦合金REWR之單因子變異數分析....................................................................47
表4-5放電加工鈦合金Ra之單因子變異數分析......................................................................48

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