臺灣博碩士論文加值系統

本論文的目的在於自行設計並製作一套可同時量測三個軸向研磨接觸力的被動式量測系統。本系統是針對CNC加工中心的工作床台所設計，可量測的最大加工接觸力，X軸及Y軸皆為200牛頓，Z軸則為250牛頓。可量測的最小刻度則三軸皆為0.0096牛頓。
這套系統主要分成動力計本體及周邊兩大部份，動力計本體則包含了支撐平台、保護外殼以及量測基座等機構。其中，量測基座乃是以韌性及強度佳的彈簧鋼為材料，並利用有限元素法對量測基座進行了機構降伏、應變分佈以及力量干涉等分析。動力計本體所感測到的結果經由訊號放大器放大，類比訊號轉換乘數位訊號後，利用VIEWDAC軟體進行讀取、儲存及繪圖整理。
作者利用這套設備，量測研磨加工過程中之研磨力。研磨加工係將手持研磨機裝置於數值控制工具機之上進行研磨。作者針對三種研磨路徑、三種模具常用材料、三種研磨頭轉速、三種工具機進給速率及三種刀具直徑進行研磨實驗，並探討這些因素對於三軸研磨力及表面粗糙度的影響。研磨結果以田口法進行分析，透過變異數分析各研磨條件對三軸研磨力及表面粗糙度之貢獻率，得知研磨路徑對研磨接觸力的影響最大，工件材料次之，再來則為加工進給率及刀具直徑，研磨頭轉速則幾乎沒有影響。至於表面粗糙度方面，主要是以刀具直徑於表面粗糙度的影響為最大，亦即刀具直徑愈大，表面粗糙度愈小。

In this thesis, a strain gage dynamometer is designed and manufactured to measure three dimensional grinding forces during grinding processes. With a resolution of 0.0096Nt in all 3 directions, this dynamometer is able to measure 2 tangential grinding forces in the range 0.0096 to 200Nt, and the normal grinding force in the range 0.0096 to 250 Nt. The dynamometer is composed of 4 measuring blocks to which strain gages are attached. Measuring blocks are designed so that, upon application of forces, they deform in a way that forces in the x, y, and z directions can be separated with little interaction. These results were confirmed by finite element analyses.
The dynamometer is then used to measure grinding forces of the grinding process, the motion which is produced by a hand grinder mounted on the spindle of a NC machine. Results are given for 3 commonly used materials for molds, 3 hand grinder speeds, 3 feed rates for the NC machine, 3 different grinding paths , and 3 diameters of grinding tool. Effects of these factors on grinding forces are investigated. By using the analysis of variance of the Taguchi method, influence of each on all grinding forces (i.e. 2 tangential forces in the x and y direction, the normal force in the z direction, and the resultant force) are obtained.
It is found that grinding paths is the most influential factor on all grinding forces. All grinding forces decrease when grinding paths turn along smoother arcs. The second-most influential factor on grinding forces is workpiece material. All grinding forces increase with hardness of materials

目錄
中文摘要
英文摘要
目錄 IV
圖目錄 VI
表目錄 XI
符號說明 XII

第一章 緒論 1
1.1 研究動機及源起 1
1.2 研究目的 3
1.2.1 動力計製作 3
1.2.2 手動研磨機加工時加工的接觸力資料 4
1.2.3 分析與歸納較佳的研磨條件 4
1.3 文獻回顧 5
1.3.1 研磨力量的量測方式 5
1.3.2 影響研磨接觸力及表面粗糙度的研磨參數 7
1.3.2.1 影響研磨接觸力的參數 7
1.3.2.2 影響工件表面粗糙度的參數 8
1.3.2.3 同時影響研磨接觸力及工件表面粗糙度的參數 9
1.3.3 研磨力量量測的應用情形 10
1.5 研究流程 12

第二章 實驗儀器設計與原理 13
2.1 量測基座設計 13
2.2 三軸式動力計本體硬體構造 18
2.3 量測系統基本架構 21
2.4 應變規原理與技術 23
2.5 應變規的應用電路-惠斯登電橋 26
2.6 有限元素分析 29
2.6.1 量測基座降伏應力分析 31
2.6.2 量測基座應變分析 33
2.7 三軸力量量測簡介 37
2.8 三軸量測系統干涉情形討論 46
2.8.1 X方向干涉情形 46
2.8.2 Y方向干涉情形 51
2.8.3 Z方向干涉情形 53

第三章 三維接觸力量量測與表面粗糙度的分析 54
3.1 實驗設計與計畫 54
3.2 以往復式路徑進行研磨加工時的接觸力推導 59
3.2.1 研磨頭轉動但沒有加工進給量的情形 59
3.2.2 研磨頭沒有轉動僅有加工進給量的情形 62
3.2.3 研磨頭同時具有轉動以及加工進給量的情形 63
3.3 研磨力量量測結果整理與討論 65
3.3.1 數據整理與統計 65
3.3.2 結果討論 87
3.3.2.1 研磨參數對X方向研磨接觸力的影響 87
3.3.2.2 研磨參數對Y方向研磨接觸力的影響 89
3.3.2.3 研磨參數對Z方向研磨接觸力的影響 90
3.3.2.4 研磨參數對研磨接觸力之合力影響 92
3.3.2.5 研磨力量量測結果整體趨勢討論 93
3.4 往復式路徑時研磨參數對表面粗糙度之影響 94
3.4.1 研磨加工參數對平均粗糙度的影響 94
3.4.2 研磨加工參數對最大粗糙度的影響 96

第四章 結論與建議 99

參考文獻 101

附錄一 SUP-6彈簧鋼的機械性質量測 105

附錄二 惠斯登電橋串聯電路推導 107

附錄三 研磨力量量測系統量測步驟 110

附錄四 三軸研磨力量量測結果圖 112

附錄五 實驗設備與情形 139

附錄六 三軸力量量測系統規格 142

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