臺灣博碩士論文加值系統

表面粗糙度(Surface Roughness)是現代精密機械加工非常重要的指標之一，並常受到不同參數的影響，包括刀具的選擇。本研究利用電腦數控(CNC)銑床進行平面銑削加工，來研究6061鋁基複合材料之表面粗糙度。銑削加工係使用三種不同形狀端銑刀具，亦即平面型、球型、圓鼻型端銑刀，並依不同的銑削參數包括主軸轉數、進給速度和銑削深度，於固定的銑削間隔與銑削路徑進行銑削加工。物件加工採用線型袋型(Pocketing)銑削路徑，並使用表面粗糙度儀和光學顯微鏡分析與探討各條件銑削加工之表面粗糙度。研究結果顯示出在三種不同形狀端銑刀銑削下，表面粗糙度隨進給速率改變的影響較主軸轉速顯著。同時銑削深度對表面粗糙度所產生的效應，在球型及平面型端銑刀者較圓鼻型端銑刀為大。三者刀具形狀所得到的粗糙度依優劣排序為：圓鼻型端銑刀＞平面型端銑刀＞球型端銑刀。本研究之結果提供業界在6061鋁基複合材料精密端銑加工應用上的重要參考。

Surface roughness is one of the most important indices for the modern precision machining and can be affected by different factors including the choice of cutting tools. In this study, the surface roughness of plain milling for 6061 aluminum matrix composite is investigated by using computer numerical control (CNC) milling machine. Three types of end mill, i.e. flat end mill, ball end mill and bull nose cutter, are also used for milling operations. The cutting process is varied with different parameters such as spindle rotational speed, feed rate and cutting depth under constant cutting path and interval. The mechanical parts are machined with a linear pocketing path. Furthermore, the surface roughness is measured and evaluated by means of the roughness meter and optical microscopy. The experimental result shows that for all three types of end mill, the effect of feed rate on the surface roughness is more evident than that of spindle rotational speed. Furthermore, the variation of the surface roughness with cutting depth is more obvious for the ball end mill and flat end mill than that for bull nose cutter. Finally, the bull nose cutter has the best surface roughness followed by flat end mill and ball end mill. The current results provide a valuable reference for the industrial application of 6061 aluminum matrix composite in high precision end milling process.

致謝.....................................................................................................................I
摘要....................................................................................................................II
Abstract..........................................................................................................III
目錄..................................................................................................................IV
表目錄.............................................................................................................VII
圖目錄...........................................................................................................VIII
符號表............................................................................................................XII
第一章 緒論......................................................................................................1
1.1 前言.........................................................................................................1
1.2 文獻回顧.................................................................................................2
1.3 研究動機與目的.....................................................................................4
第二章 理論基礎..............................................................................................5
2.1 切削理論.................................................................................................5
2.2 銑削參數...............................................................................................10
2.2.1 銑削速度......................................................................................10
2.2.2 進給率..........................................................................................11
2.2.3 銑削深度......................................................................................12
2.2.4 銑削間隔......................................................................................13
2.2.5 銑削種類......................................................................................14
2.3 刀具種類...............................................................................................17
2.3.1 刀具材料......................................................................................17
2.3.2 CNC刀具種類...........................................................................19
2.4 表面粗糙度...........................................................................................22
2.4.1 表面粗糙度形成..........................................................................22
2.4.2 表面粗糙度表示法......................................................................24
第三章 實驗設備與方法................................................................................27
3.1 實驗規劃流程.......................................................................................27
3.2 實驗設備...............................................................................................28
3.2.1 三軸CNC工具...........................................................................28
3.2.2 表面粗糙度儀............................................................................30
3.2.3 光學顯微鏡................................................................................32
3.3 實驗材料...............................................................................................34
3.3.1 刀具介紹....................................................................................34
3.3.2 加工材料....................................................................................35
3.4 實驗步驟...............................................................................................39
3.5 實驗參數...............................................................................................40
第四章 實驗結果與討論................................................................................41
4.1 平面型端銑刀對量測數據分析及探討...............................................41
　4.2 光學顯微鏡下對平面型端銑刀銑削表面觀測分析及探討...............42
　4.3 平面型端銑刀量測數據.......................................................................43
4.3.1 平面型端銑刀量測數據分析......................................................44
4.3.2 平面型端銑刀表面紋路變化......................................................48
4.4 圓鼻型端銑刀對量測數據分析及探討...............................................52
　4.5 光學顯微鏡下對圓鼻型端銑刀銑削表面觀測分析及探討...............53
　4.6 圓鼻型端銑刀量測數據.......................................................................54
4.6.1 圓鼻型端銑刀量測數據分析......................................................55
4.6.2 圓鼻型端銑刀表面紋路變化......................................................59
　4.7 球型端銑刀對量測數據分析及探討...................................................63
　4.8 光學顯微鏡下對球型端銑刀銑削表面觀測分析及探討...................64
　4.9 球型端銑刀量測數據...........................................................................65
4.9.1 球型端銑刀量測數據分析..........................................................66
4.9.2 球型端銑刀表面紋路變化..........................................................70
4.10 三種端銑刀具綜合比較.....................................................................74
第五章 結論....................................................................................................78
未來展望..........................................................................................................80
參考文獻..........................................................................................................81

1.D.Y. Jang, Y.G. Choi, H.G. Kiam, A. Hsiao, “Study of the correlation between surface roughness and cutting vibrations to develop an on-line roughness measuring technique in hard turning”, International Journal of Machine Tools and Manufacture 36, 1996, 453-464.
2.A.E. Diniz, J.C. Filho, “Influence of the relative positions of tool and workpiece on tool life, tool wear and surface finish in the face milling process” , Wear 232, 1999, 67-75.
3.K.K. Kim, M.C. Kang, J.-S. Kim, Y.H. Jung, N.K. Kimb, “A study on the precision machinability of ball end milling by cutting speed optimization”, Journal of Materials Processing Technology 130-131, 2002, 357–362.
4.T.S. Smith, R.T. Farouki, M.A. Kandari and H. Pottmann, “Optimal Slicing of Free-Form Surfaces”, Computer Aided Geometric Design 19, 2002, 43-64.
5.B.C. Irene, V.C. Joan, D.F. Alejandro, “Surface topography in ball-end milling processes as a function of feed per tooth and radial depth of cut”, International Journal of Machine Tools & Manufacture 53, 2012, 151–159.
6.E.S. Topal, “The role of stepover ratio in prediction of surface roughness in flat end milling”, International Journal of Mechanical Sciences 51, 2009, 782–789.
7.G.E. D'Errico, E. Guglielmi, G. Rutelli, “A study of coatings for end mills in high speed metal cutting”, Journal of Materials Processing Technology 92-93, 1996, 251-256.
8.鄭忠賢，不同鍍膜端銑刀對SUS304之銑削特性探討，機械工程學系碩士論文，成功大學，2002。
9.呂建興，球銑加工表面粗糙度之分析，機械與電腦輔助工程學系碩士論文，逢甲大學，2011。
10.尤世承，球型端銑刀加工曲面之表面粗糙度及精度探討，機電工程學系碩士論文，華梵大學，2009。
11.李昭佐，端銑刀之傾角、螺旋角與鍍膜對銑削硬鋼工件表面粗糙度之影響，機電工程學系碩士論文，華梵大學，2007。
12.吳忠信，端銑刀銑削表面粗糙度之分析，材料與製造工程機械工程組碩士論文，逢甲大學，2008。
13.邱肇彥，三軸工具機銑削路徑之精加工表面研究，機械工程學系碩士論文，台灣大學，2011。
14.呂立鑫、林秀賢、張昀、張廷政、張庭瑞、喻立信、蔣祥第、蕭錫謙編譯，機械製造第九版，高立圖書有限公司，2008。
15.唐文聰編譯，切削加工技術，全華科技圖書股份有限公司，1992。
16.S.A. Coker,Y.C. Shin, “In-process control of surface roughness due to tool wear using a new ultrasonic system”, International Journal of Machine Tools and Manufacture 36, 1996, 411-422.
17.蔡德藏編著，工廠實習-機工實習，全華科技圖書股份有限公司，2006。
18.elearningDJ.com編著，MastercamⅩ實戰演練，加樺國際有限公司，2007。
19.洪良德、陳正仁、陳昌順、謝壬揆、李鈞澤、傅光華編著，切削刀具學，高立圖書有限公司，1992。
20.沈金旺編著，CNC綜合切削中心機程式設計與應用，全華圖書股份有限公司，2011。
21.黃廷合編著，機工精密測量，全華科技圖書股份有限公司，1993。
22.唐文聰編譯，精密機械加工原理，全華科技圖書股份有限公司，2004。