臺灣博碩士論文加值系統

本研究使用鐵粉組成之臥式磁刷工具，探討加工負荷(0.5 N~1.05 N) 、鐵粉重量(0.1 g~0.2 g)與磁刷定型(自然成型、事先定型)對磁刷與工件接觸後的接觸面積與高度之影響。
在工件與工具皆不旋轉時，當鐵粉重量增加，接觸面積與磁刷高度會增加。此外，當加工負荷的增加，接觸面積也會增加，而磁刷高度則會降低，然後趨近飽和值。事先定型磁刷之接觸面積會小於自然成型磁刷；而事先定型磁刷之高度則會大於自然成型磁刷。在工件旋轉且工具不旋轉時，接觸面積會略為增加，而磁刷高度則會略為降低。磁刷會沿著工件旋轉的方向產生偏移，部分的磁刷鏈結會斷裂。在工件與工具皆旋轉時，接觸面積則會大幅增加，而磁刷高度會大幅降低。
最後使用氧化鋁磨粒加入鐵粉，在鐵粉重量0.2 g、事先定型磁刷、加工負荷0.65 N、工具旋轉並加入加工液與磨粒進行循環，對304不鏽鋼圓柱工件進行加工，觀察加工表面粗糙度的變化。在工件轉速400 rpm、工具旋轉60 rpm及加工時間8分鐘後，表面粗糙度從Ra =0.257 µm、Rmax = 1.025 µm下降至Ra = 0.021 µm、Rmax = 0.91 µm。

In this study, a horizontal magnetic brush tool composed of iron powders was used to investigate the effects of the load (0.5 N~1.05 N), the iron powder weight (0.1 g~0.2 g) and the magnetic brush shaping (natural forming, pre-shaping) on the contact area and height after the contact between the magnetic brush and the workpiece. When the workpiece and the tool were not rotating, the contact area and the height of the magnetic brush increased along with the weight of the iron powders. In addition, as the load increased, the contact area also increased, while the magnetic brush height decreased and then approached a saturation value. The contact area of the pre-shaped magnetic brush was smaller than that of the naturally formed magnetic brush; and the height of the pre-shaped magnetic brush was greater than that of the naturally formed magnetic brush. When the workpiece is rotated and the tool is not rotating, the contact area was slightly increased and the magnetic brush height was slightly decreased. The magnetic brush shifted in the direction of rotation of the workpiece, and some of the magnetic brush links was broken. When both the workpiece and the tool were rotated, the contact area was greatly increased, and the height of the magnetic brush was greatly reduced.
Finally, the 304 stainless steel cylindrical workpiece was polished using circulating cutting fluid mixed alumina abrasive grains and iron powders to observe the variation of the surface roughness of the workpiece at the weight 0.2 g of the iron powders, the load of 0.65 N, the pre-shaping magnetic brush, and the rotating tool. Results showed that the surface roughness could decreases from Ra =0.257 µm、Rmax = 1.025 µm to Rmax = 0.091 μm、Ra = 0.021 μm after a polishing time of 8 minutes at the rotating speed 400 rpm of workpiece, and the rotating speed 60 rpm of the tool.

論文審定書 i
誌謝 ii
摘要 iii
Abstract iv
目錄 vi
表次 xvii
第一章 緒論 1
1.1 前言 1
1.2研究動機 1
1.3文獻回顧 2
1.2.1磁性研磨的加工原理 2
1.2.2 磁性研磨的加工行為 3
1.2.3 磁性研磨的研磨刷行為 5
1.2.4磁性工具的垂直壓緊力特性之闡明 8
1.2.5磁極形狀的影響 10
1.2.6現有的磁性研磨實驗相關參數與加工狀態 12
1.2.7複雜表面研磨之進展 18
1.4研究目的 21
2.1磁性研磨加工之實驗設備 23
2.1.1 磁性研磨工具機 23
2.1.2 直流電源供應器 41
2.1.3表面粗度儀與其相關配備 42
2.1.4分析天平 44
2.2實驗材料 45
2.2.1工件材料幾何形狀 45
2.2.2加工液 46
2.3實驗說明 47
2.3.2實驗參數 49
2.3.4 實驗步驟 51
第三章 實驗結果與討論 55
3.1 工件未旋轉之純鐵粉磁刷與工件接觸後的磁刷變形結果 55
3.1.1工件未旋轉時鐵粉重量與加工負荷影響純鐵粉磁刷變形結果 56
3.1.2工件未旋轉時磁刷定型影響純鐵粉磁刷的變形結果 64
3.1.3工件未旋轉時工具擺向影響純鐵粉磁刷的變形結果 68
3.1.4工具未旋轉時純磁刷工具與工件接觸後的磁刷變形結論 73
3.2動態之實驗結果 73
3.2.1工件旋轉時鐵粉重量與加工負荷影響純鐵粉磁刷的變形結果 74
3.2.2工件旋轉時磁刷定型影響純鐵粉磁刷的變形結果 83
3.2.3工件旋轉時磁刷定型影響純鐵粉磁刷的變形結果 86
3.2.4工具旋轉時純磁刷工具與工件接觸後的磁刷變形結論 92
3.3磁刷與工件接觸後的鐵粉區之鐵粉殘留量 92
3.3.1鐵粉重量與加工負荷的鐵粉區之鐵粉殘留量關係 93
3.3.2工具擺向與鐵粉區之鐵粉殘留量的關係 96
3.3.3鐵粉區之鐵粉殘留量結論 98
3.4 加入氧化鋁磨粒後的磨粒精加工的結果 99
3.4.1不同擺向之磨粒精加工的結果 99
3.4.2不同磁刷定型之磨粒精加工的結果 102
3.4.3不同鐵粉重量之磨粒精加工的結果 104
3.4.4不同加工負荷之磨粒精加工的結果 107
3.4.5切削液非循環與循環的差異 109
3.4.6 加入氧化鋁磨粒後的磨粒精加工的結論 117
第四章 結果與未來研究方向 118
4.1 結論 118
4.2 未來研究方向 120
參考文獻 121

[1]T. Shinmura,“ Development of Magnetic Abrasive Finishing Apparatus using Vibratory Magnetic Poles and Its Finishing Performance”, Journal of the Japan Society for Precision Engineering, Vol. 54, No. 11, 1988, pp. 2170-2175.
[2]T. Shinmura, Y. Shinbo and T. Iizuka, “ A New Internal Finishing Process of a Non-ferromagnetic Tubing by Applying a Rotating Magnetic Field- The Development of Finishing Equipment for Practical Use and Its Finishing Performances-”, Journal of the Japan Society for Precision Engineering, Vol. 59, No. 6, 1993, pp. 81 – 86
[3]J. D. Kim and M. S. Choi, “Study on magnetic polishing of free-form surdaces ”, Int. J. Mneh. Tools Manufaet. Vol. 37, No. 8, 1997, pp. 1179-1187.
[4]H. Yamaguchi, T. Shinmura and S. Watanabe,“ Study of a Magnetic Field Assisted Internal Finishing Process using Abrasive Slurry Circulation System -Effects of Geometrical and Magnetic Properties of Magnetic Particles on the Finishing Characteristics-”, The Japan Society for Precision Engineering, Vol. 67, No. 3, 2001, pp. 444 – 449.
[5]Y. Zou and T. Shinmura,“ Study on Internal Magnetic Field Assisted Finishing Process Using a Magnetic Machining Jig”, Key Engineering Materials，Vols. 291-292，pp.281-286，2005．
[6]川久保英樹和蓬田達也,“ 磁気援用加工法によるＲ溝面の仕上げ特性” 2006 年度精密工学会秋季大会学術講演会講演論文集ID: J07
[7]S. L. Ko, Y. M. Baron, J. I. Park,“Micro deburring for precision parts using magnetic abrasive finishing method”, Journal of Materials Processing Technology Vol. 187–188, 2007, pp.19–25.
[8]梁國柱,王阿成,連俊彥,林宣良和林書弘，“磁力研磨於滾珠螺桿螺旋拋光的應用研究(II) ”，台灣行政院國家科學委員會專題研究計畫2011, NSC 100-2221-E-231-010-
[9]鄒艶華和M. R. Muhamad, “電解複合したパイプ内面磁気研磨法に関する研究”, 2014 年度精密工学会春季大会学術講演会講演論文集, I47, pp. 469-470.
[10]鄒艶華, “磁石工具を用いた曲がり管内面の精密仕上げに関する研究”, 2015 年度精密工学会春季大会学術講演会講演論文集”,J24, pp. 593-594.
[11]鄒艶華, “磁性加工ジグを用いた内面磁気援用加工法に関する研究（キーノートスピーチ）”, 2016 年度精密工学会春季大会学術講演会講演論文集,L13, pp. 613-614.
[12]鄒艶華和解文成,“ 磁石工具を用いた曲がり管内面の精密仕上げに関する研究”, 2016 年度精密工学会春季大会学術講演会講演論文集, R33,pp. 967-968.
[13]藤原健太和鄒艶華,“磁気研磨法を利用した樹脂パイプ内外面の精密仕上げに関する研究”, 2016 年度精密工学会春季大会学術講演会講演論文集, M31,pp. 801-802.
[14]T. Shinmura, K. Takazawa, E.Hatano and T. Aizawa, “Study on Magnetic-abrasive Finishing (2nd Report) – Finishing Characteristics -”, The Japan Society for Precision Engineering, Vol. 52, No. 10, 1986, pp. 1761 – 1767.
[15]進村武男和波田野栄十，“磁気研磨法の研究-永久磁石を利用した研磨装置の試作-，日本精密工学会誌Vol. 53, No. 3, (1987) pp. 497 – 500
[16]M. Anzai, T. Sudo, H. Otaki, T. Obana and T. Nakagawa, “Magnetic Finishing of WC-Co Alloy Using Diamond Paste”, Journal of the Japan Society of Powder and Powder Metallurgy, Vol. 39, No. 6, 1992, pp. 510-514.
[17]T. Shinmura, F. H. Wang and T Aizawa, “Study on a New Finishing Process of Fine Ceramics by Magnetic Abrasive Machining -On the Improving Effect of Finishing Efficiency Obtained by Mixing Diamond MagneticAbrasives with Ferromagnetic Particles-”, Journal of the Japan Society for Precision Engineering, Vol. 59, No. 8, 1993, pp. 1251-1256.
[18]L. Ma, T. Furuki, W. Wu, T. Hirogaki and E. Aoyama, “Elucidation of the polishing mechanism by the magnetic polishing brush”, Transactions of the JSME, Vol. 82, No. 844, 2016, pp. 1 – 12.
[19]M. Natsume and T. Shinmura, “Study on the Mechanism of Plain Magnetic Abrasive Finishing Process(Elucidation of Normal Force Characteristics)”, Transactions of the Japan Society of Mechanical Engineers, Series C, Vol. 74, No. 737 (2008) , pp. 212-218.
[20]T. Shinmura, K. Takazawa and E. Hatano, “Study on Magnetic-abrasive Finishing (1st Report)– On Process Principle and a Few Finishing Characteristics - “, The Japan Society for Precision Engineering, Vol. 52, No. 5, 1986, pp. 851 – 857.
[21]H. Yamaguchi and T. Shinmura，“Study of the surface modification resulting from an internal magnetic abrasive finishing process “, Vol 225–229, Part 1, 1999, PP. 246-255
[22]進村武男和山口ひとみ，“円筒磁気研磨法に関する研究-磁性砥粒の挙動と研磨圧力発生のメカニズム-“，日本精密工学会誌 Vol. 62, No. 2, 1996, pp. 258-259.
[23]T. Mori, K. Hirota and Y. Kawashima，“Clarification of magnetic abrasive finishing mechanism”, Journal of Materials Processing Technology Vol. 143–144 , 2003, PP. 682–686.
[24]D. K. Singh, V. K. Jain, V. Raghurama and R. Komanduri，“Analysis of surface texture generated by a flexible magnetic abrasive brush” Wear Vol. 259, 2005, PP. 1254–1261
[25]進村武男和王鳳輝，“鉄粉混合砥粒 を用 いた硬ぜい材料の平面磁気研磨法とその研磨特性“，日本精密工学会誌Vol. 60, No. 11 , (1994), pp. 1652-1653.
[26]H. Kawakubo, K. Tsuchiya, U. Satoh, T. Yamazaki, K. Miki and Y. Tezuka, “Surface magnetic polishing using spindle through type magnetic pole- Influence of particle brush on polishing characteristics- ”, 日本砥粒加工学会誌Vol. 46, No.8, 2002, pp. 401-406
[27]C. W. Kum ,T. Sato, J. Guo, K. Liu and D. Butler“A novel media properties-based material removal rate model for magnetic field-assisted finishing ” International Journal of Mechanical Sciences Vol.141, 2018, pp.189–197
[28]T .Kayaba, K. Kato and T. Akagaki” Ferrographic study of wear(first report)the fundamental characteristics of magnetic wear debris separation analysis”,J.JSLE, Vol.29, 1984, pp. 745-752.