臺灣博碩士論文加值系統

本文以半離散法探討週期性弦波主軸轉速變化對端銑削加工穩定性的影響。利用週期性的主軸轉速變化可改變每刃切削週期，進而影響切削震紋相位差並打斷再生效應，從而抑制再生顫震的發生。為了釐清變轉速切削之使用時機以及各項系統參數對本方法抑制顫震效果之影響，本文模擬變轉速振幅、變轉速頻率、系統模態參數、切削系數、製程阻尼係數等對變轉速系統穩定性的影響。經由模擬結果發現主要影響本方法抑制顫震效率的要素為變轉速振幅、頻率與製程阻尼。在不同的額定轉速下需要挑選適當的變轉速振幅以及頻率才能有效抑制顫震。而製程阻尼則會大幅增加低轉速時的銑削穩定性，並提高變轉速系統的極限切深曲線之漸近轉速。但考慮製程阻尼後會使半離散法收斂所需的離散點數增加，導致模擬所需時間大幅增加。除此之外，從模擬結果來看在定轉速切削的極限切深曲線局部低點之轉速下施行變轉速切削，其提升穩定性的效果是最好的。而在甜蜜區部分施行變轉速切削效果較差，甚至會使原本穩定的切削系統轉為不穩定。而其餘模態參數、刃數以及剪切係數基本上不太影響變轉速提升穩定性的效果。實驗結果亦證實了本方法在發生顫震時可有效降低加工時的振動量。

In this study, effect of sinusoidal spindle speed variation on end milling is investigated based on semi discretization method. Tooth passing period is changed by period spindle speed variation, then result in interruption of regernerative effect and supress chatter. In order to clarify effect of system parameters on variable speed machining stability, effect of variation amplitude, variation frequency, modal parameters, shearing constant and process damping coefficients on stability of variable speed system is investigated in the present study. The results of simulation show that the dominant parameters are variation amplitude, variation frequency and process damping coefficients. Appropriate amplitude and frequency should be choosed to supress chatter at different nominal spindle speed. Process damping effect increases milling stability at low speed region dramatically and increases the asymptotic speed, which is absolutely stable speed. But semi discretization method including process damping also takes longer simulation time. The results of simulation also show that variable speed machining suppress chatter effectively at local worst speeds, that is, the speeds that have lowest stable cutting depth. But such method cause negative effect on sweet spot, transform the machining system from stable to unstable. Modal parameters, flute number, and shearing coefficients do not affect the efficiency of improving the milling stability by variable speed machining. Experimental results also show that variable speed machining can reduce vibration amplitude when chatter is occurring.

摘要 i
Abstract ii
誌謝 xv
目錄 xvi
表目錄 xviii
圖目錄 xix
符號表 xxiii
第一章 緒論 1
1.1 研究動機與目的 1
1.2 文獻回顧 2
1.2.1 切削穩定性分析 2
1.2.2 變轉速切削抑制顫震 5
1.3 研究範疇與論文架構 6
第二章 銑削力模型與銑削穩定性分析 8
2.1 動態銑削力模型 8
2.1.1 剪切力 8
2.1.2 犁切力 11
2.2 半離散法簡介 13
2.3 銑削穩定性分析 16
2.4 銑削穩定圖與時域數值模擬 19
第三章 週期性主軸轉速變化對端銑削穩定性的影響 23
3.1 週期性主軸轉速變化對時間延遲項的影響 23
3.2 變轉速銑削系統穩定性分析 28
3.3 系統參數對變轉速銑削穩定性的影響 33
3.3.1 不同變轉速頻率比RVF的穩定性模擬 34
3.3.2 不同變轉速振幅比RVA的穩定性模擬 43
3.3.3 不同徑向切深比的穩定性模擬 53
3.3.4 模態參數、剪切係數及刃數對穩定性的影響 58
3.3.5 製程阻尼對穩定性的影響 63
第四章 驗證實驗 68
4.1 結構參數及切削系數量測實驗 68
4.2 切削顫震實驗與變轉速切削實驗 73
4.2.1 切削顫震實驗 73
4.2.2 變轉速切削實驗 80
第五章 結論與建議 94
5.1 結論 94
5.2 建議 95
參考文獻 97

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王俊志，廖俊傑，蘇金發，穩定圖上最佳銑削切深之解析預測，中國機械工程學會第三十二屆全國學術研討會，高雄市，台灣，2015。