臺灣博碩士論文加值系統

摘要
由於機械技術的高度發展，對產品精度的需求逐漸增加。一般而言，精密零組件大多都得經過多次加工製程才能滿足需求；針對複雜外型之精密元件，其表面加工往往以銑削完成，銑削後若需較佳的表面，則應進行後續處理(如磨削、拋光等)。然而磨削、拋光作業必須在不同加工機具上完成，拆裝卸和製程安排時相當耗時，若能在銑削後於相同之工具機上直接進行磨削加工，後續在進入拋光製程，必能減少加工成本。

本研究利用一表面披覆CBN磨粒的球狀磨刀，在現有的CNC加工機上針對工件表面進行精加工實驗，期望能以球狀磨刀所進行的加工製程，作為銑削後進入拋光前的中間製程。並藉由磨削實驗的規劃與進行，觀察磨削過程中之磨削力、磨刀與工件表面狀況的各項變化，將觀察所得做詳細的紀錄與分析，以作為探討磨削行為的依據。

針對磨削實驗所獲得的磨削力訊號，經運算處理後發現，所計算出之磨削力變異大小，可藉以用來作為磨削行為的描述；在經由分析後得知，磨削力變異與磨粒磨損呈正比關係。另外也發現，磨刀表面面粗度之變化可觀察出磨粒的磨損情形，面粗度值越低表示磨粒磨損越顯著。而在實驗數據中，低主軸轉速與高進給速率情況下，磨粒磨損尤為明顯。因此藉由實驗的探討，提供了CBN-磨刃在磨削過程中磨削行為的觀察，作為後續使用時之參考依據。

Abstract
Due to high development of the mechanical technology, the needs of the precise components are being increased. Conventionally, most of the precision parts need multiple manufacturing processes; in accordance with the machining of curved surface, the work surface is usually generated using a milling operation to obtain the required geometry. A subsequent finishing operation, such as grinding or polishing, is performed if a better surface is required. Usually, this is done on a different machine tool. Extra set up time and additional non-production time are thus required.

This study is to utilize a ball-nose tool coated with CBN abrasive, to fine grind the milled work surface. The process done by the ball-nose tool is intended to be an effective substitute for as-milled finishing operation. In this study, the designed tool was loaded into a machining center as a typically milling cutter. Planning and proceeding the grinding experiment, and observing the change of the grinding force, the condition of the abrasive cutter and the work surface in the grinding process. The results are recorded and analyzed in the grinding process, in accordance with investigation of grinding behavior.

After computing the grinding force of the experimental results, the variation of the grinding force was obtained describe the grind behavior. After proper analysis, the variation of the grinding force was found to be directly proportional to the grain abrasion. Besides, wheel grain abrasion was found to be affected the surface roughness of the abrasive cutter. When surface roughness becomes too smooth, would indicate an apparent abrasion of the wheel surface. The lower the spindle speed and the higher the feed rate, the abrasion of the grain would easily become more remarkable. The result of this research, provide an observation of the grinding behavior of the CBN-abrasive in the process, which thus give good reference for subsequent use.

目錄
摘要 I
ABSTRACT II
致謝 IV
目錄 V
圖目錄 VIII
表目錄 XI
符號索引 XII

一、緒論 1
1.1前言 1
1.2研究動機與目的 2
1.3論文架構 3
二、文獻探討 4
2.1 球狀磨刀之設計 4
2.1.1 概念構想 4
2.1.2 磨粒選用 5
2.2 製程線上監控 8
2.2.1製程感測裝置 8
2.2.2 磨削力對加工製程的影響 10
2.3 製程訊號處理 11
三、球狀磨刀之使用與磨削實驗之規劃 13
3.1 CBN球狀磨刀之設計概念 13
3.2 CBN球狀磨刀之實作 15
3.3 磨粒之磨削行為 18
3.4 磨削力訊號擷取與後續處理 21
3.4.1 磨削力訊號擷取 21
3.4.2 磨削力訊號的後續處理與應用 24
3.4.3 磨削力行為的分析與觀察 27
3.5 實驗規劃與實驗設備 31
四、實驗結果與討論 38
4.1 加工參數對磨削力之變異的影響 38
4.2 磨削力之變異與磨刀表面粗糙度的關係 42
4.3 磨削力之變異與磨刀上磨粒層厚度的關係 45
4.4 磨削力之變異與工件移除體積的關係 48
4.5 磨削力之變異與工件表面粗糙度之關係 50
五、結論與討未來展望 52
5.1 結論 52
5.2 未來展望 54
六、參考文獻 55
附錄一 LABVIEW程式 60
附錄二 小波轉換(WAVELET TRANSFER)理論 62
附錄三 表面粗糙度值 65
附錄四 實驗分析圖檔 70

參考文獻
【1】陳慶芳，民國85年，”模具拋光路徑與表面形貌之整合研究”，淡江大學機械工程研究所，碩士論文，6月。
【2】林嘉彥，民國88年，”模具研磨過程中之三維研磨力量量測”，淡江大學機械工程研究所，碩士論文，2月。
【3】N. Asakawa, Y. Takeuchi, 1997, “Dexterous Polishing of Sculptured Surfaces Robot Automatic Selection I-Shape and L-Shape Rotational Tool”, Seminar Manufacturing Systems, Vol.29, pp. 370~375, Japan。
【4】林維新，民國82年，CBN磨輪研削加工技術，初版中國砂輪企業股份有限公司，6月。
【5】K. Subramanian, R.P. Lindsay, 1996, ”A Systems Approach for the Use of Vitrified Bonded Superabrasive Wheels for Precision Production Grinding”, Journal of Emgineering for Industry , Vol.45, pp.42~52。
【6】M. Yokogawa, K. Yokogawa, 1992, “Improvements in Work Surface Integrity and Material Fatigue Strength by the CBN Wheel Process”, Japan Society of Precision Engineering, Vol.26, pp.201~206。
【7】M. Yokogawa, K. Yokogawa, 1992, “Effects of Nickel Coated Abrasives on the Grinding Performance of Resin Bonded CBN Wheels”, Japan Society of Precision Engineering, Vol.26, pp.108~114。
【8】M. Yokogawa, K. Yokogawa, 1992, “Grinding Properties of Monocrystalline and Microcrystalline CBN Grinding Wheels”, Japan Society of Precision Engineering, Vol.26, pp.20~26。
【9】A. Ishibashi, S. Tanaka, S. Ezoe, 1986, “Super Precision Gear Grinder with CBN Grinding Wheel”, Japan Society of Precision Engineering, Vol.20, pp. 294~295。
【10】S. Malkin, “Current Trends in CBN Grinding Technology”, Annals of the CIRP, Vol.34, pp.606~611。
【11】E. Gotou, M. Touge, 1996,“Monitoring of wear of Abrasive” , Journal of Materials Processing Technology, Vol.34, pp. 408~414。
【12】T.W. Hwang, E.P. Whitenton, N.N. Hsu, G.V. Blessing, C.J. Evans, 2000, ”Acousticemission monitoring of high speed grinding of silicon nitride”, Ultransonics, Vol.38, pp.614~619。
【13】H.K. Tonshoff, M. Jung, S. Mannel, W. Rietz, 2000, ”Using acoustic emission signalsfor monitoring of production processes”, Ultrasonics, Vol.37, pp.681~686。
【14】P. Srinivasa Pai, P.K.Ramakrishna Rao, 2002, “Acoustic Emission Analysic for Tool Wear Monitoring in Face Milling”, International Journal of Production Research, Vol. 40, pp. 1081~1093。
【15】A. Saravananriyan, L. Vijayaraghavan, R. Krishnamurthy, 2001,“On-line Dectection of Grinding Burn by Integrated Sensing” , Slcon’ 01Sensors for Industry Conference Rosemount, pp.5~7, USA。
【16】陳鴻榮，2002，”磨削能量對磨後工件表面品質之探討”，國立高雄 第一科技大學，碩士論文。

【17】馮倉碩，2003，”判斷砂輪再削銳時機之監控系統的建構”，國立高雄第一科技大學，碩士論文。
【18】E.S. Lee, N.H. Kim, 2001,”A study on the machining characteristics inthe external plunge grinding using the current signal of the spindlemotor”,International Journal of Machine Tools & Manufacture, Vol.41 , pp. 937~951。
【19】X. Li, A. Djordjevich, P.K. Venuvinod, 2000, “Current -Sensor-Based Feed Cutting Force Intelligent Estimation and Tool Wear Condition Monitoring”, IEEE Transactions on Industrial Electronics, Vol. 47, pp. 697~702。
【20】G.J. Trmal, P.S. Midha and C.B. Zhu, 1992, “An Expert System for Grinding Process Optimisation.“, Journal of Materials Processing Technology, Vol. 33, pp. 507~517。
【21】M. Younis, 1987,“A new approach to development of a grinding force model”, Trans. ASME, Vol.109, pp. 306~313。
【22】I. Fukumoto, S. Itomura, 1988, “An Evaluation of Grinding force by the Fracture Toughness on Carbon Steel. ” , Mach. Tools Manufacture, Vol. 29。
【23】徐世穹，民國91年， ”瓷質CBN砂輪磨削工具剛性能之分析”，華梵大學機電工程研究所，碩士論文，6月。
【24】M. Touge, H. Sakamoto, T. Matsuo, 1994, ”Jig Grinding of Condition on Grinding Characteristics” ,Trans cations of the Japan Society for Precision Mechanical Engineers, Part c 60 576 , pp. 2845~2851。
【25】G.J. Trmal, P.S. Midha, and C.B. Zhu, 1992, “An Expert System for Grinding Process Optimisation.” , Journal of Materials Processing Technology, Vol. 33, pp. 507~517。
【26】S. Gu, J. Ni, J. Yuan, 2002,”Non-stationary signal analysis and transient machining process condition monitoring”, International Journal of Machine Tools & Manufacture, Vol.42, pp.41~51。
【27】M. Misra, H.Henry Yue, S.Joe Qin, C. Ling, 2002, ”Multivariate process monitoring and fault diagnosis by multi-scale PCA”, Computers and Chemical Engineering, Vol.26, pp1281~1293。
【28】J. Chen, C.M. Liao, 2002, ”Dynamic process fault monitoring based onneural network and PCA”,Journal pf process control ,Vol.12, pp277~289.
【29】L. Xiaoli, Y. Zhejun, 1998, ”Tool wear monitoring with wavelet packet transform-fuzzy clustering method”, Wear, Vol.219, pp.45~154。
【30】S. Malkin, 1989,”Grinding Technology Theory and Plication of Machining with Abrasives”, ELLIS HORWOOD LIMITED, Vol.11, pp.301~304。
【31】福田力也，民國81年1月，磨削作業法，賴耿陽譯，建宏出版社，pp.22~24。
【32】賴耿陽，民國88年12月，砂輪磨床工作技術，復漢出版社，pp.25~27。
【33】林信隆，1991，精密鑽石工具，台灣鑽石工業股份有限公司。
【34】賴耿陽，民國90年6月，精密加工新技術全集，復漢出版社， pp.153~158。
【35】趙芝眉，湯銘權，1989，金屬切削原理，科技圖書股份有限公司，台北。
【36】黃忠良，民國88年12月，新研磨技術與設備，復漢出版社， pp.11~13。
【37】黃國良,，1990，“以小波表達城市幾何表面之新方法”， 成功大學，測量工程研究所，碩士論文。
【38】J. Morlet, A. Grossmann, 1989, “ Decomposition of Hardy Functions Into Square Integrable Wavelets of Constant Shape,” SIAM J., Math. 15, pp.723。
【39】單維彰， 2000，凌波初步， 全華圖書。
【40】林展生， 2003，”利用小波轉換分析電力品質”， 淡江大學，電機工程研究所，碩士論文。
【41】吳杉堯，民國82年3月，精密量具及機械檢驗實習，大揚出版社。