臺灣博碩士論文加值系統

本文目的在探討以熱壓燒結的方式製作五種不同石墨含量(0.1、0.5、1、3、5 wt％)固態且具有潤滑效果的新式石墨砂輪（GIGW），立式磨削工具鋼材料之性能分析，使用三種不同的冷卻潤滑方式進行實驗: 乾磨削和微量潤滑（MQL）與微量水霧(MQM)，並與傳統的砂輪作比較。新式石墨砂輪製作方法為將具有微米等級的石墨粉末添加於氧化鋁砂輪中，在加熱爐中通入氫氣，溫度約為 500°C，持續30分鐘後能使石墨粉末能均勻分散，減少團聚現象，將氫化石墨砂輪順利製作完成。利用SEM觀察磨削過程後與工件表面之變化，量測表面粗糙度、磨削溫度、與磨削力的分佈，並探討工件表面形貌、計算砂輪磨耗等。實驗結果顯示：添加石墨含量0.1%與3%可得到較佳的表面粗糙度和表面形貌，並有效的降低磨削溫度和磨削力，也因為減少砂輪的磨耗率，因此也間接的提高砂輪的使用壽命，如需要較大的磨削深度時，3%的石墨含量可以滿足加工需求，但添加石墨含量至5%時，雖然也可以保有相當的工件表面品質，但砂輪消耗率將大幅提升，本研究讓微量潤滑(MQL)與氫化過的新式石墨砂輪（GIGW）的互相配合，不但可以減少在磨削過程中因為一般普遍使用油類或有毒的有機潤滑油，造成環境的污染與工件品質的惡化，也能保有相當的砂輪壽命與工件表面品質。

This paper aims to investigate ways to produce sintered five different graphite content (0.1,0.5,1,3,5 wt%) solid and has a lubricating effect of the new graphite wheel (GIGW), vertical grinding tool steel materials performance analysis, using three different cooling lubrication experiment: dry grinding and minimal quantity lubrication (MQL) and minimal quantity mist (MQM), and compared with the conventional wheel. New method for the production of graphite wheel will have a micron rating of graphite powder added to alumina grinding wheel, in the pass into the hydrogen furnace, the temperature is about 500 ° C, for 30 minutes to make graphite powder can be evenly distributed, reducing the agglomeration , the hydrogenated graphite wheels smoothly finished. Observed by SEM after the grinding process of the change of the surface, measuring the surface roughness, grinding temperature, and the grinding force distribution, and to explore the surface morphology, such as calculation of wheel wear. The results showed: 0.1% added graphite content available with 3% better surface roughness and surface morphology, and effectively reduce the grinding temperature and grinding forces, but also because of reduced wheel wear rate and, therefore, indirectly increase wheel of life, such as the need for greater grinding depth, 3% of the graphite content to meet the processing needs, but added graphite content to 5%, although it could retain considerable surface quality, but the grinding wheel consumption rate will be significantly upgrade, this study has MQL (MQL) and hydrogenated over a new graphite wheel (GIGW) with each other, not only can reduce the grinding process because the general widespread use of oil or toxic organic lubricant, causing environmental pollution and deterioration in the quality of the workpiece, but also retain considerable wheel life and surface quality.

目錄

致 謝 I
中 文 摘 要 II
英 文 摘 要 IV
目 錄 VI
表 目 錄 VIII
圖 目 錄 IX
第 一 章 緒論 1
1.1 前言 1
1.2 研究動機與目的 3
1.3 文獻回顧 4
1.3.1 切削液(油) 4
1.3.2 MQL 發展史 5
1.3.3 MQL 相關研究 7
1.3.4 油霧系統的優缺點 9
1.4 固體潤滑 10
1.4.1 常用固體潤滑材料 10
1.4.2 金屬潤滑材料 11
1.4.3 高分子固體潤滑材料 11
1.4.4 石墨之結構、特性與應用 12
1.4.5 固體潤滑之相關研究 16
第 二 章 理論基礎 17
2.1 磨削加工基本原理 17
2.2 砂輪構成的要素 17
2.2.1 砂輪規格介紹 19
2.2.2 砂輪研磨工件中之現象 21
2.2.3 砂輪修整與修銳 22
2.3 磨削過程中的切削行為 23
2.4 平面磨削加工特色 24
2.5 磨削加工參數 24
2.6 磨削力 24
2.7 磨削能與比磨削能 26
2.8 砂輪磨耗比 26
2.9 砂輪磨損 26
第 三 章 實驗機台架構 28
3.1 機台設計 28
3.2 液靜壓軸承 28
3.3 人機介面設計 30
3.4 MQL 油霧機 31
3.5 冷凍式空氣乾燥機 32
3.6 機台實驗系統配置 33
第 四 章 砂輪製作及實驗與量測設備 34
4.1 實驗方法 34
4.2 砂輪之製作 34
4.3 實驗設備 45
第 五 章 實驗結果與討論 51
5.1 砂輪分析試驗 51
5.1.1 砂輪微觀結構 51
5.1.2 熱分析儀DSC 53
5.2 砂輪磨削試驗 57
5.2.1 不同含量石墨氧化鋁樹脂砂輪對於砂輪磨耗之差異性 57
5.2.2 不同含量石墨氧化鋁樹脂砂輪對於表面粗糙度之影響 60
5.2.3 不同含量石墨氧化鋁樹脂砂輪對於溫度之影響 64
5.2.4 不同含量石墨氧化鋁樹脂砂輪對於磨削力之影響 65
5.2.5 不同含量石墨氧化鋁樹脂砂輪對於表面形貌之影響 70
第 六 章 結論及未來展望 77
6.1 結論 77
6.2 未來展望 79
參考文獻 80

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