臺灣博碩士論文加值系統

現在市面上滾珠螺桿的製作拋光方法，大多為粗磨、細磨、精磨經過這幾個步驟就會形成滾珠螺桿。然而這種加工方法要經過2次加工所以時間較久。磁力研磨是一種快速且高精度的拋光方法，但在研磨材料滾珠螺桿時，會降低導磁性磨料之磁力，並且，因產生的離心力易將磨料拋離加工區域，進而降低拋光的穩定性。
本研究主要是針對導磁性膠體磨料在不銹鋼管內對滾珠螺桿的拋光效率，我們進而開發不同的膠體當結合劑，將導磁性磨粒與硬質磨粒拘束於膠體內部，形成導磁性膠體磨料，因膠體磨料具有黏滯性，不但可以將磨粒包覆住，讓磨粒不易飛散，且膠體磨料可以緊密貼附在滾珠螺桿表面，增加拋光的穩定性。本研究主要是將導磁性膠體磨料置入在不銹鋼管管內對滾珠螺桿的拋光，並依不同黏滯性之膠體，且搭配不同加工參數，探討其表面粗糙度及材料移除量的變化。再利用田口實驗法來建立膠體磁力研磨的最佳化參數。為了減少實驗的嘗試次數，先利用ANSYS分析磁極的最佳磁場分佈情形，並設計出適合使用於滾珠螺桿拋光的磁極形狀。依實驗結果顯示，使用黏度較低之水性沙皮膠，對滾珠螺桿加工30分鐘後，表面粗糙度可由0.368μm Ra降至 0.061μm Ra，材料移除量更是高達311mg，證實了本文所開發的導磁性膠體磨料實驗法對滾珠螺桿具有優異的拋光效果。

The finishing of ball screw in the market is mostly by procedures of coarse, fine and precision grinding. However, these finishing methods must undergo two processes thus they require longer time. Magnetic abrasive finishing is a fast and high precision approach, but the magnetism of magnetic abrasive is reduced when finishing ball screw, and because the centrifugal force generated tends to throw abrasive away from the processing area, the stability of finishing is thus decreased.

This study mainly focuses on the effect of the magnetic gel abrasives in stainless steel pipe on the finishing efficiency of ball screw. We developed different gels as binders and restrained magnetic and hard abrasive grains in the gels to form magnetic gel abrasives. Since the gel abrasives are viscous, they can not only wrap around the abrasive grains to prevent from spreading, but also attach tightly onto the surface of ball screw. We placed the magnetic gel abrasives in stainless steel pipes to conduct finishing on ball screws, and collocated different processing parameters based on different gel viscosity to investigate the changes in surface roughness and material removal rate. The Taguchi method was applied for establishing optimal parameters for magnetic gel abrasive finishing. In order to reduce the number of experiments performed, ANSYS was used for analyzing the optimal magnetic distribution of magnetic poles, and a magnetic pole shape suitable for ball screw finishing was designed. The results showed that after 30min of ball screw finishing using aqueous slime gel with lower viscosity, the surface roughness can be decreased from 0.368μm Ra to 0.061μm Ra, and the material removal rate can be as high as 31.1mg. This proves that the magnetic gel abrasive finishing developed in this study has outstanding finishing effect on ball screws.

摘 要 i
英文摘要 ii
誌謝 iii
目錄 iv
表目錄 vii
圖目錄 viii
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 5
1.4 論文架構 11
第二章 實驗原理 12
2.1 膠體磁力研磨加工之基本原理 12
2.2 膠體 15
2.2.1膠體之黏滯性 15
2.3 表面粗糙度 16
2.4田口式品質穩健設計法 19
2.4.1田口式實驗法與傳統實驗之差異 20
2.4.2品質特性 23
第三章 實驗設備與方法 25
3.1 實驗設備 25
3.2 實驗材料 35
3.3 實驗方法 39
3.3.1 探討實驗參數對研磨結果之影響 39
3.3.2 田口法實驗 41
3.3.3 探討不同形狀之磁極對磁場的影響 43
3.3.4 不同磁極形狀對表面粗糙度之探討 44
第四章 結果與討論 45
4.1 探討不同形狀之磁極對磁場的影響 45
4.2 不同磁極形狀對表面粗糙度之探討 48
4.2.1 不同磁極形狀對研磨結果的影響 48
4.3 實驗結果 49
4.3.1 分別添加鋼砂與鐵粉對研磨結果的影響 50
4.3.2 不同膠體對研磨結果的影響 52
4.3.3 不同碳化矽濃度對研磨結果的影響 55
4.3.4 不同鐵粉濃度對研磨結果的影響 58
4.3.5 不同碳化矽粒徑對研磨結果的影響 60
4.3.6 不同鐵粉粒徑對研磨結果的影響 62
4.3.7 不同迴轉速度對研磨結果的影響 64
4.3.8 不同往復速度對研磨結果的影響 66
4.3.9 不同電流大小對研磨結果的影響 68
4.4 田口法實驗 70
4.4.1 田口法實驗結果(表面粗糙度) 70
4.4.1.1 變異數分析(表面粗糙度) 74
4.4.1.2田口法實驗之最佳參數驗證結果(表面粗糙度) 75
4.4.2 田口法實驗結果(材料移除量) 76
4.4.2.1 變異數分析(材料移除量) 78
4.4.2.2 田口法實驗之最佳參數驗證結果(材料移除量) 79
4.5 試片表面研拋之研拋結果 81
第五章 結論 83
參考文獻 85
簡 歷 92

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