臺灣博碩士論文加值系統

近年來隨著航太業的興起，銑削高硬度合金材料成為現今主流趨勢之一，然而加工時的穩定性會隨著機台剛性、材料性質以及刀具幾何有所差異，目前國內銑削高硬度合金，大多依靠操作者的加工經驗、提高加工安全係數或採用離線模擬的方式，迴避加工時的顫振發生。線上即時的顫振迴避技術是以感測器檢測顫振的特徵變化，並搭演算法進行加工參數優化，當顫振發生時機台將具有自我調適的能力，能夠有效率的迴避顫振使加工穩定。本研究主要分為刀具智能化顫振補償與雲端物聯網兩個系統，首先是刀具智能化顫振補償系統建置，其中包含銑削穩定建模以及切削參數優化演算法，銑削穩定模型分為切削力係數計算、刀具動剛性實驗以及銑削穩定圖建置，切削力係數計算透過切削力的變化量測與線性回歸法，鑑別出刀具幾何外型對於鋁合金7075-T6之切削力係數，刀具動剛性實驗以加速度規與敲擊錘進行敲擊實驗，將敲擊實驗取得之頻譜響應資料進行分析，計算出X與Y方向的模態參數，銑削穩定模型建置，將切削力係數與模態參數代入Altintas等人所提出之顫振穩定曲線演法，建立出主軸轉速與切削深度之間的關係。切削參數優化演算法，以顫振穩定預測模型作為加工參數優化的依據，最短距離搜尋法與梯度上升做為參數調整的演算法，進行最佳加工參數的搜尋，當偵測到切削狀態屬於不穩定加工時，透過最短距離搜尋法，取得距離目前最近之臨界穩定參數，將其參數以梯度上升法計算出該峰值最佳的切深以及轉速，並回饋穩定轉速於控制器中達到穩定狀態。雲端物聯網系統，從底層資料蒐集機台加工資訊，經由平台層中的MQTT Broker與PostgreSQL管理與儲存雲端資料，將加工時中的顫振資訊存入資料庫中，讓使用者更方便的調整加工中製程參數，最後雲端資料的呈現，將透過應用層訂閱MQTT Broker中的資訊，並且以網頁呈現機台加工中的所有資訊。

In recent years, the aerospace industry is rising, milling of high hardness alloy materials has become trend; however, the stability of milling is changed with machine rigidity, material properties and tool geometry. The traditional experience method has not been able to deal with chatter of processing. On-line chatter suppression technique can be used to avoid the unstable cutting conditions by milling stability model and obtaining the stable maching parameters. This study is divided into intelligent chatter suppression and IoT coud patform systems. Intelligent chatter suppression system is built, which includes milling stability modeling and cutting parameter optimization algorithm. The stability model of milling is divided into three parts. First, the cutting forces are estimated using dynamic meter and the cutting force coefficients are calculated using linear regression in process, the cutting force coefficient experimental results show that the same tool and material properties at different depths have an average error of 5% to 19%. Second, the spindle model parameters of the cutting tool system are estimated by dynamic rigidity experiment. Furthermore, the stability model of milling for chatter is based on professor Altintas, and this stability model constructs a relationship between the spindle speed and cutting depth by regenerative chatter theory and frequency respond function, the chatter stability model verification experimental results of slot show that the initial prediction accuracy is about 90%. When chatter is detected on-line, the optimal parameters of cutting is obtained from gradient rising and shortest distance of search algorithm methods according to stability model of milling, and provides stable processing conditions to the controller. The second part focuses on IoT cloud platform, the experiment data and processing information are collected from CNC controller of five-axis machine tool, and the CNC controller uploads the data to cloud platform to manage and store. The chatter information in processing is stored in the database, so that user can more easily adjust the parameters during the processing. The cloud website will present all of processing information.

摘要.....i
英文摘要(Abstract).....ii
誌謝.....iii
目錄.....iv
表目錄.....vi
圖目錄.....vii
符號說明.....ix
第 一 章 緒論.....1
1.1 研究背景與動機.....1
1.2 研究目的.....2
1.3 論文架構.....2
第 二 章 文獻回顧.....3
2.1 切削力係數相關研究.....3
2.2 銑削顫振穩定預測相關研究.....6
2.3 線上即時顫振抑制相關研究.....9
第 三 章 研究架構與方法.....13
3.1 研究架構與流程.....13
3.2 硬體及系統架構.....14
3.2.1 切削力實驗硬體設備.....14
3.2.2 刀具動剛性實驗硬體設備.....15
3.2.3 實驗材料與刀具規格.....16
3.2.4 實驗機台介紹.....16
3.3 端銑刀之切削力模型解析.....17
3.3.1 切削力解析.....17
3.3.2 端銑刀切削力模型.....18
3.3.3 平均切削力模型.....20
3.4 切削力係數鑑別.....21
3.4.1 動態切削力量測實驗.....21
3.4.2 基於平均切削力模型鑑別切削力係數.....22
3.5 動態銑削之顫振穩定預測.....23
3.5.1 刀具動剛性實驗分析.....23
3.5.2 顫振穩定曲線計算.....24
3.6 動態切削振動監控與線上即時補償.....27
3.6.1 刀具之顫振監控系統.....27
3.6.2 梯度上升與與最短距離搜尋法的應用.....28
3.6.3 線上即時顫振迴避.....30
3.7 雲端看板系統建置.....31
3.7.1 雲端系統架構介紹.....31
3.7.2 MQTT通訊協定介紹.....32
3.7.3 資料庫介紹.....33
第 四 章 實驗結果.....35
4.1 切削力係數鑑別.....35
4.1.2 切削力量測實驗.....35
4.1.3 平均切削力與回歸分析.....37
4.2 線上顫振迴避系統建置.....39
4.2.1 刀具動剛性實驗.....40
4.2.2 顫振穩定模型預測.....42
4.2.3 切削實驗規劃與顫振穩定模型驗證.....43
4.2.4 動態銑削監控系統.....49
4.2.5 智能化顫振抑制系統.....50
4.3 雲端系統建置.....51
4.3.1 PostgreSQL資料庫建立.....52
4.3.2 MQTT雲端訊息管理系統.....52
4.3.3 雲端網頁建置.....53
第 五 章 結論與未來展望.....55
參考文獻.....56
Extended Abstract.....58

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