臺灣博碩士論文加值系統

微鑽針直徑小、高細長比(Aspect Ratio)的特性，常使得微鑽針在鑽孔過程中，受到過大的鑽削力而斷裂。本研究以斜交與正交兩種切削模式推導微鑽針鑽削時推力和扭矩，主要切削邊採取斜交切削而鑿刃邊為正交切削，應用刀具在切削工件時剪切面受力情況，逐一推導求得主要切削邊、鑿刃邊的切削力分佈情形，規劃全因子實驗，探討加工參數(進給速度、轉速)對切削力的影響，利用部分因子實驗設計(24-1)，安排微鑽針幾何刀型參數與切削力關係的實驗，經變異數分析、回歸分析及殘差分析得到回歸方程式，建構反應曲面圖，分析因子與因子間交互作用對切削力的影響，並最佳化微鑽針幾何刀型參數設計，最後規劃驗證實驗確認實驗之正確性。
研究結果顯示，轉速固定不變的情況下，推力與扭矩會隨進給速度的增加而遞增，相反地；當進給速度一定時，推力與扭矩會隨著轉速的增加而呈現下降的趨勢。若所有加工條件一定時，鑽尖角與蹼部厚度較小及螺旋角較大時，微孔鑽削所產生的推力較小。然而；對扭矩而言，鑽尖角與螺旋角較大及蹼部厚度較小時，所產生的扭矩較小，此外；鑽尖角與螺旋角的交互作用對扭矩也有相當大的影響。本研究結果可減少因加工參數設定不當，導致微鑽針斷裂的機會，並優化微鑽針幾何刀型設計，進一步減少切削力的產生。

The micro-drill usually breaks in drilling as a result of too great a drilling force; the reason is due to the characteristic of its small diameter and high aspect ratio. This study uses the oblique cutting model and the orthogonal cutting model coupled with the development of a thin shear zone cutting analysis to predict the thrust and torque. Not only the factorial design of experiment is used to investigate the influence of machining parameter to cutting force, but also this study utilizes 24-1 factorial design to arrange the experiment of micro-drill tool geometry and cutting force. The result of experiment comes out a regression equation through “analysis of variance”, “regression analysis” and “residual analysis”. The response surface diagram is used to analyze the impact of factors and interaction of factors to cutting force. Finally, this study optimizes the design of micro-drill tool geometry and verifies the accuracy of this experiment.
According to the result, the thrust and the torque increase with the raise of feed speed if the rotational speed is constant. On the contrary, the thrust and the torque decrease with the raise of the rotational speed if the feed speed is constant. The investigation also shows that the thrust decreases with small point angle, web thickness and large helix angle. However, the torque decreases with large point angle, helix angle and small web thickness. Beside, the interaction of point angle and helix angle affects the torque significantly. The result of this research can reduce the chance of broken micro-drills due to the wrong arrange of machining parameter. It also optimizes the design of micro-drill tool geometry to reduce the production of cutting force.

目錄
頁次
中文摘要…………………………………………………………………………………i
英文摘要……………………………………………………………………...…….…...ii
誌謝………………………………………………………………………………….….iv
目錄……………………………………………………………………………………...v
表目錄…………………………………………………………………………………viii
圖目錄…………………………………………………………………………………...x
符號表…………………………………………………………………………………xiii
一、緒論………………………………………………………………………………...1
1.1 前言……………………………………………………………………………1
1.2 研究動機與目的………………………………………………………………1
1.3 論文結構………………………………………………………………………2
二、理論基礎與文獻回顧……………………………………………………………...4
2.1 電路板製程……………………………………………………………………4
2.2 微鑽針…………………………………………………………………………5
2.2.1 微鑽針材質…………………………………………………………….5
2.2.2 微鑽針製程…………………………………………………………….6
2.2.3 微鑽針幾何外型……………………………………………………….7
2.3 微孔鑽削與傳統鑽頭在技術領域上不同之處………………………………8
2.4 影響微孔鑽削因素……………………………………………………………8
2.5 文獻回顧………………………………………………………………………9
三、微孔鑽削力理論模式…………………………………………………………….13
3.1 正交切削與斜交切削………………………………………………………..13
3.2 主要切削邊切削力關係式…………………………………………………..14
3.3 鑿刃邊切削力關係式………………………………………………………..18
3.4 總推力與總扭矩……………………………………………………………..21
3.5 結語…………………………………………………………………………..21
四、實驗方法與步驟………………………………………………………………….22
4.1 實驗目的……………………………………………………………………..22
4.2 實驗流程與步驟……………………………………………………………..22
4.2.1 加工參數實驗………………………………………………………...23
4.2.2 幾何參數實驗………………………………………………………...24
4.2.3 實驗步驟……………………………………………………………...24
4.3 實驗儀器與設備……………………………………………………………..25
五、結果與討論……………………………………………………………………….26
5.1 前言…………………………………………………………………………..26
5.2 統計檢定……………………………………………………………………..26
5.3 精鍊模式……………………………………………………………………..27
5.4 殘差分析……………………………………………………………………..29
5.5 結果說明……………………………………………………………………..30
5.5.1 加工參數實驗………………………………………………………...30
5.5.2 幾何參數實驗………………………………………………………...32
5.6 誤差之原因探討……………………………………………………………..35
5.7 驗證…………………………………………………………………………..37
六、結論與未來展望………………………………………………………………….39
6.1 結論…………………………………………………………………………..39
6.2 未來展望……………………………………………………………………..41
參考文獻……………………………………………………………………………….42
附錄一 電路板鑽孔機鑽孔程式…………………………………………………….103

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