臺灣博碩士論文加值系統

鎳基合金是典型的耐熱合金，它具有高硬度、高溫強度、熱穩定性佳和抗腐蝕性等特性，近年來已被廣泛應用於航太、石化工業等，需長期在高溫環境下工作的設備零件中。雖然鎳基合金具有良好的抗氧化性和抗高溫變形性等機械性質，但亦有導熱係數低和加工硬化等問題，使得切削時切削熱易集中於刀尖，造成刀具因高溫產生嚴重的擴散磨耗、氧化磨耗和粘結磨耗。加工後鎳基合金表面硬化十分嚴重，其加工硬化的程度約為正常表面硬度的2倍；切屑硬度高、韌性佳且不易折斷，造成切削過程中斷屑困難；而材料中金屬化合物和硬質點較多，容易造成刀具崩刃，難以保證尺寸與精度要求。
本論文主要討論切削鎳基超合金Waspaloy時，通過設定不同的切削速度、每刃進給量與切深等切削參數，來觀察刀具磨耗量與Waspaloy的表面粗糙度如何變化。藉由實驗所得到的結果導出刀具壽命公式，並從其中探討何種切削參數對於切削Waspaloy有顯著的影響。
由實驗結果可以得知，切削速度對於切削Waspaloy的影響最為顯著，故加工時不建議使用高速切削。而在表面粗糙度的部分，我們可以發現當刀具磨耗越大Waspaloy的表面粗糙度會比理論值來得差。
最後，可由上述所得到的結果建立一組數學模型來預測：當切削刀具具有磨耗時，於加工後Waspaloy的表面粗糙度會落在多少數值，而其預測值與實際值的誤差為5.122% ~8.646%；如果此刀具所加工的表面粗糙度還在容許範圍內，便預測此刀具加工至完全損壞時，剩餘使用時間為多久，而其預測值與實際值的誤差範圍為8.014% ~ 20.479%。

Nickel-based alloys are typical heat-resistant alloys, that have high hardness, high temperature-strength, good thermal stability, corrosion resistance and other characteristics. In recent years, they have been widely used in equipment parts which require long-term work in high temperature environment in aerospace, petrochemical and other industries. Although nickel-based alloys have good resistance to oxidation, high temperature deformation and other mechanical properties, but there are also low thermal conductivity, work-hardening and other issues. So the cutting heat is easy to focus on the nose in cutting, causes the cutting tool due to high temperature to bring serious diffusion wear, oxidation wear and adhesion wear. The surface hardening of nickel-based alloys after cutting is very serious. The degree of work hardening has increase 2 times than the normal surface hardness. The chip has high hardness, good toughness and difficult to break, caused it is difficult to breaker the chip in the cutting process. And that is a lot of metal compounds and hard particles in the material. It is easy to cause the tool break, and difficult to ensure that the size and accuracy requirement.
This paper focuses on cutting nickel-based superalloy Waspaloy. By setting different cutting speed, feed rate per tooth, cutting depth and other cutting parameters, to observe the amount of tool wear and Waspaloy’s surface roughness how to changes. The results obtained by experiment export tool life equation, and explore which cutting parameters for cutting Waspaloy has a significant impact.
From the experimental results can know. The impact of cutting speed is most significantly for cutting Waspaloy. So the processing does not recommended to using high-speed cutting. From the part of the surface roughness, we can see when the tool wear is bigger that the Waspaloy’s surface roughness will come worse than the theoretical value.
Finally, the result obtained by the above build a set of mathematical model to predict. When the cutting tool has the tool wear, the Waspaloy’s surface roughness will get how much value after machining. The error of the predicted value and the actual value is between 5.122% and 8.646%. If this tool machined surface roughness is still within the acceptable range. Predict when this cutting tool to full damage, and the remaining using time is how long. The error of the predicted value and the actual value is between 8.014% and 20.479%.

摘要 --------------------------------------------------I
ABSTRACT ---------------------------------------------II
誌謝 -------------------------------------------------IV
目錄 --------------------------------------------------V
圖目錄 ----------------------------------------------VII
表目錄 -----------------------------------------------IX
第一章 緒論 --------------------------------------------1
1-1 前言 ----------------------------------------------1
1-2 文獻回顧 -------------------------------------------3
1-3 研究目的 -------------------------------------------4
1-4 論文架構 -------------------------------------------5
第二章 實驗材料與刀具的介紹 ------------------------------6
2-1 Waspaloy超合金的應用 -------------------------------6
2-2 Waspaloy超合金的特性 -------------------------------6
2-2-1 Waspaloy超合金的金屬性質 --------------------------6
2-2-2 Waspaloy超合金的強化機構 --------------------------9
2-2-3 Waspaloy超合金的切削性質 -------------------------10
2-3 刀具材料 ------------------------------------------11
2-4 刀具種類 ------------------------------------------14
2-4-1 高速鋼 -----------------------------------------14
2-4-2 超硬合金刀具 ------------------------------------14
2-4-3 陶瓷刀具 ----------------------------------------17
2-4-4 披覆刀具 ----------------------------------------18
2-4-5 鑽石與氮化硼(CBN)刀具 ----------------------------20
第三章 相關理論 ---------------------------------------21
3-1 切削理論 ------------------------------------------21
3-1-1 銑刀介紹 ----------------------------------------21
3-1-2 銑削原理 ----------------------------------------23
3-1-3 銑削形式 ----------------------------------------23
3-1-4 切刃接觸形式 ------------------------------------25
3-1-5 切削力學 ----------------------------------------26
3-1-6 切削條件 ----------------------------------------27
3-2 刀具破壞理論 --------------------------------------28
3-2-1 磨耗 -------------------------------------------29
3-2-2 刀具磨耗因素 ------------------------------------31
3-3 刀具壽命 ------------------------------------------33
3-4 表面粗糙度理論 ------------------------------------34
3-5 實驗設計法概論 ------------------------------------39
3-5-1 試誤法 -----------------------------------------40
3-5-2 一次一因子實驗法 ---------------------------------40
3-5-3 全因子實驗法 ------------------------------------40
3-5-4 2^(k-p)部分因子實驗法 ---------------------------42
3-5-5 2^k一半因子實驗法 -------------------------------42
3-5-6 反應曲面法 --------------------------------------42
第四章 實驗設備與方法 ----------------------------------45
4-1 實驗設備 ------------------------------------------45
4-1-1 立式綜合加工機 ----------------------------------45
4-1-2 切削刀具 ----------------------------------------46
4-1-3 數位顯微鏡 --------------------------------------47
4-1-4 表面粗糙度量測儀 ---------------------------------49
4-2 實驗方法 ------------------------------------------50
第五章 實驗結果與討論 ----------------------------------53
5-1 刀具壽命公式 --------------------------------------53
5-2 切削參數的影響 ------------------------------------60
5-3 刀腹磨耗與表面粗糙度的關係 --------------------------61
5-4 刀具壽命預測 --------------------------------------66
第六章 結論與未來展望 ----------------------------------73
6-1 結論 ---------------------------------------------73
6-2 未來展望 ------------------------------------------74
參考文獻 ----------------------------------------------75

【1】F. Campbell, 2006, Chapter 6 - superalloys, in: F. Campbell (Ed.), Manufacturing Technology for Aerospace Structural Materials, Elsevier Science, Oxford, pp. 211 – 272.
【2】李名言，2013，〝鎳基合金材質特性介紹〞，中工高雄會刊，第21卷，第1期，頁23~30，9月。
【3】洪于展，2013，〝鎳基合金在航太零組件之應用商機〞，金屬情報網。
【4】自動化在線，2011，〝航空用鎳基高溫合金切削現狀研究〞，at：http://www.autooo.net/utf8-classid78-id78814.html
【5】C. Salomon, 1931, Process for the Machining of Metals and Similarly Acting Materials When Being Worked by Cutting Tools, German Patent No.523594.
【6】林學良，89年，〝不同披覆刀具對銑削MAR-M247之影響〞，國立中正大學，碩士論文。
【7】Wright, P.K., and Chow, J.G., 1982, 〝Deformation Characteristics of Nickle Alloys During Maching〞, ASME, Journal of Engineering for Industry, Vol.104, pp.85-93.
【8】M. Nalbant, 2007, 〝The effect of coating material and geometry of cutting tool and cutting speed on machinability properties of Inconel 718 superalloys〞, Materials and design, Vol.28, pp1719-1724.
【9】Hanasaki,S., Fujiwara, J. Touge,M., and Hasegawa,Y., 1990, 〝Tool wear of Coated Tools When Machining a High Nickel Alloys〞, Annals of the CIRP, Vol.39/1, pp.77-80.
【10】M. Nalbant, et al., 2007, 〝The effect of cutting speed and cutting tool geometry on machinability properties of nickel-base Inconel 718 superalloys〞, Materials and design Vol.28, pp1334-1338.
【11】A. Jawaid, S. Koksal, S. Sharif, 2001, 〝Cutting performance and wear characteristics of PVD coated and uncoated carbide tools in face milling Inconel 718 aerospace alloy〞, Journal of Materials Processing Technology 116 (2001) 2-9.
【12】Miroslav Zetek, 2014, 〝Increasing Cutting Tool Life when Machining Inconel 718〞, Procedia Engineering, Vol.69, pp1115-1124.
【13】王璽皓，87年，〝類鑽薄膜披覆銑刀耐磨耗性之研究〞，國立成功大學，碩士論文。
【14】蔡坤潭，101年，〝電漿輔助加工於超合金Inconel-718之研究〞，國立勤益科技大學，碩士論文。
【15】洪成淼，姚志浩，張麥倉，董建新，張玉峰，2008年，〝Waspaloy合金碳化物和γ'相析出規律的熱力學計算〞，北京科技大學學報，第30卷，第9期，頁1018~1023。
【16】ROLLED ALLOYS，at：http://www.rolledalloys.com/alloys/cobalt-alloys/waspaloy/en/
【17】切削材料-KC，at：http://wenku.baidu.com/view/fab574ed6294dd88d0d26b68.html
【18】Hui-Yun Bor, 1998, 〝A Study on the Elevated Temperature Brittleness and Fracture Mechanism of Mar-M247 Superalloy〞, National Chiao Tung University.
【19】Kear, B.H., O’blak, J.M. and Giami, A.F., 1970, 〝Stacking faults in Gamma Prime Precipitation Hardened Nickel-Base Alloys〞, Metallurgical Transacions, Vol.1, pp2477-2486.
【20】陳志名，83年，〝面銑削Inconel718刀具破壞之研究〞，國立台灣大學，碩士論文。
【21】周奇輝，81年，〝碳化物鍍層刀具對銑削MAR-M247鎳基超合金之探討〞，國立中正大學，碩士論文。
【22】傅光華，2003，〝切削刀具學〞，高立圖書有限公司。
【23】SANDVIK，〝工件材料組〞，at：http://www.sandvik.coromant.com/zh-cn/knowledge/materials/workpiece_materials/workpiece_material_groups/pages/default.aspx
【24】Metalworking World Magazine，〝The multiple challenges of machining ISO P workpiece materials〞，at：http://www.metalworkingworldmagazine.com/the-multiple-challenges-of-machining-iso-p-workpiece-materials/
【25】瀋陽航空航天大學，〝刀具材料〞，at：http://ie2009.sau.edu.cn/page/Default.asp?ID=176
【26】李鈞澤，2006，〝切削刀具學〞，新文京開發出版有限公司。
【27】Geoover，2008，〝機械製造〞，高立圖書有限公司，pp342。
【28】陳紹賢，89年，〝Inconel-718與AISI4340銑削性探討〞，國立中正大學，碩士論文。
【29】F.W. Taylor, 1906, 〝On the art of cutting metals〞, Trans. ASME, pp29-31.
【30】張郭益，范光照，1998，〝精密量具及機件檢驗〞，高立圖書有限公司，pp264-268。
【31】原晉廷，〝扣件表面粗糙度〞，技術論壇，pp114-118。
【32】精密銑削專輯　精密加工百科，1991。
【33】黎中正譯，2003，Montgomery著，〝實驗設計與分析〞，第五版，高立圖書有限公司。
【34】D.C. Montgomery, 2001, 〝Design and Analysis of Experiment〞, 5th, New York.
【35】黎中正譯，2006，Montgomery著，〝實驗設計與分析〞，第六版，高立圖書有限公司。
【36】蘇立凱，99年，〝CNC控制器與切削最適化參數調整之研究〞，國立勤益科技大學，碩士論文。
【37】蕭瑜佐，2008，〝單軸進給平台定位精度之最佳組裝參數研究〞，國立中興大學，碩士論文。
【38】清華大學品質研究中心，〝反應曲面法介紹〞。