臺灣博碩士論文加值系統

高性能之軍事航空級轉子引擎之氣封元件加工技術一般為引擎製造商之機密技術關鍵，並不容易得知氣封元件使用的材料配方及加工製造製程。業界於轉子引擎氣封元件加工是先將合金鑄件研磨至所需加工尺寸，其送至放電線切割加工切割出所要之輪廓與尺寸。其缺點為線材成本高且耗時、合金鑄件在放電線切處因高溫產生熔融而相變及應力應變層而使得合金鑄件變形量增大，所以轉子引擎氣封元件之機械性能不佳、線材成本高和加工耗時等缺點。有別於業界以放電線切割製程。本研究針對轉子引擎之合金灰口鑄鐵氣封元件之特性開發新式加工製程技術。本計畫提出三種新製程方式來加工轉子引擎氣封元件: (a)車銑複合製程、(b)銑削製程以及(c)搪削製程，並自製新式砂輪磨削工具和自製球拋光工具，將合金鑄件於加工機上進行切削、研磨、拋光。
研究結果顯示，車銑複合加工製程擁有製程簡單、成本低、加工時間快之優點，但礙於鑄件形狀使得加工受到限制，且鑄件在夾持時油壓夾頭壓力與切削力之間難以從中取得適切之平衡，容易因壓力過重或過輕使鑄件產生應力變形或在切削過程中掉落，評估車銑複合製程並不適合加工轉子引擎氣封零件；在銑削精加工製程中，利用銑削取代車削鑄件以得到符合要求之尺寸精度及表面粗糙度氣封元件，且相較於放電線切割加工出之氣封元件有更佳尺寸精度，但此製程在CNC銑床粗加工時銑刀磨耗較快。為了因應量產之成本考量，所以本計畫在後期階段初步嘗試導入搪削加工製程來改善，相較於銑削製程，使用搪刀製程得到更佳尺寸穩定性氣封元件，但搪刀加工之氣封元件內徑(ID)表面粗糙度較差於銑削製程，未來將增加搪刀刃數、轉速及和進給來優化。綜合比較，新式加工製程相較於業界放電線切割製程縮減時間成本，車銑、銑削和搪削加工製程端面之表面粗糙度(Ra0.131µm)皆優於放電線切割製程之平均表面粗糙度。氣封元件之表面形貌經過研磨及拋光加工後獲得平均表面粗糙度Ra0.019 μm相較於銑削加工製程提升精度6.9倍。

The processing technology of gas seal of high-performance military aircraft-grade rotary engine is normally the secret technology of engine manufacturer. It is not easy to know Grey cast iron alloy recipe and professional processing process. For industry-rotor engine air seal parts processing, they will first grind the alloy casting to a desired processing dimension, and then sent into Wire Electrical Discharge Machining processing plant to cut out the outline of the desired size. This method has a disadvantage of the high cost and the time consuming, alloy castings will generate melting phase transformation and stress-strain layer because of the high temperature of discharge wire cutting, and makes alloy castings deformation increases, resulting in rotary engine’s gas seal greatly ineffective. The plan proposes three new process methods for machining rotory engine air-sealing components: (a) Turn-milling process, (b) Milling process and (c) Boring process. Furthermore, the alloy castings are cut, ground, and polished on a processing machine by using self-manufactured new grinding wheel grinding tools and self-made ball polishing tools. The results of the study show that the turning-milling compound machining process has the advantages of simple process, low cost, and fast processing time. However, due to the shape of the casting, the machining is limited, and the pressure between the hydraulic chuck head and the cutting force is hard to match between the castings. Obtaining a proper balance, easily causing stress deformation of the casting due to excessive pressure or light weight, or falling during cutting, it is estimated that the turning and milling compounding process is not suitable for machining the rotor engine sealing parts. In the milling and finishing process, milling is used in place of turning castings to obtain dimensional accuracy and surface roughness components that meet the requirements. Compared with the Wire Electrical Discharge Machining process, the sealing components have better dimensional accuracy, but the wear of the milling cutters was larger in the CNC milling process. For the sake of cost considerations for product volume production, the project initially attempted to introduce boring machining processes at a later stage to improve. Compared to milling processes, a better dimensional accuracy stability of gas sealing was obtained using the boring process, however, the surface roughness of the inner diameter (ID) of the gas sealing was inferior to the result of the milling process. The boring process benefits can be optimized by adding the number of boring blades, rotation speed, and feed rate. In a comprehensive comparison, the new –developed manufacturing process reduces the time cost compared to the industry's discharge wire cutting process, and the surface roughness (Ra 0.131 μm) of the face milling, milling, and boring machining processes were all superior to the average surface roughness of the discharge wire cutting process. The average surface roughness of the air-sealed component after grinding and polishing was Ra 0.019 μm, which was 6.9 times better thanthe milling process.

第一章 緒論 1
1.1 前言 1
1.2 文獻回顧 2
1.2.1硬脆材料切削 2
1.2.2 研磨拋光 4
1.3研究動機與目的 6
1.4 本研究創新與貢獻 6
1.5 論文架構 8
第二章 磨削與拋光基礎理論 9
2.1切削理論 9
2.1.1銑削學理 9
2.2 磨削理論 11
2.2.1 未變形切削厚度 11
2.2.2 磨削力與磨削功率 12
2.2.3 砂輪磨損 13
2.2.4 砂輪與工件接觸弧長 14
2.3機械拋光基本原理 15
2.3.1 固定磨料加工 15
第三章 實驗設備與規劃 17
3.1 實驗設備 17
3.1.1友嘉HT-30Y 車銑複合機 17
3.1.2 CNC三軸立式銑床 18
3.1.3 真空高溫爐 18
3.1.4 超音波洗淨機 19
3.1.5 CNC三次元量測儀 20
3.1.6 白光干涉儀 21
3.1.7 光學顯微鏡 21
3.1.8 場發射掃描電子顯微鏡 22
3.1.9 X射線繞射分析 24
3.1.10 高轉速高精度平面磨床 24
3.1.11 指針式游標卡尺 26
3.1.12 電子式分離卡尺 26
3.1.13 砂輪動平衡校正儀 26
3.2 實驗材料及耗材 27
3.2.1 合金灰口鑄鐵 27
3.2.2 端銑刀 28
3.2.3 捨棄式刀片 29
3.2.4 搪刀把 30
3.2.5 砂輪 30
3.2.6 聚氨酯拋光棒 31
3.3 實驗規劃與進行步驟 32
第四章 結果與討論 35
4.1 合金灰口鑄鐵加工尺寸變異分析 35
4.1.1 合金灰口鑄鐵組織 35
4.1.2 尺寸變異與穩定分析 38
4.2 合金灰口鑄鐵製程參數研究 41
4.2.1 合金灰口鑄鐵銑削分析 41
4.2.2 合金灰口鑄鐵研磨拋光分析 47
4.3 氣封元件加工製程開發結果 51
4.3.1 車銑複合精加工製程 51
4.3.2 銑削精加工製程 56
4.3.3 搪削精加工製程 61
4.4 各製程成之優劣比較 63
4.4.1 不同製程之成本評估 63
4.4.2 不同製程表面粗糙度比較 65
第五章 結論與未來展望 68
5.1 結論 68
5.2 未來展望 70
參考文獻 72

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