臺灣博碩士論文加值系統

摘 要
金屬基複合材料由於具有重量輕，高強度與高剛性及可在高溫下使用等特點，可應用於航太及汽車工業上，已成為極具發展潛力的新材料。過去對金屬基複合材料其性質方面之研究上，多集中於基本機械性質、疲勞、磨耗、熱傳導與導電性等性質，對切削特性之相關研究相對較少。但由於金屬基複合材料是由較軟的金屬基材及較硬的陶瓷加強相所構成，其特點是具有高硬度與脆性但是比傳統金屬材料難切削。而其破壞特性與其表面缺陷有十分密切的關係，因此金屬基複合材料未來在實際應用上如何將其表面切削加工至所需表面光度(surface finish)及尺寸精度是當前極為重要之課題。
本研究以添加SiC之粒子強化A356鋁基複合材料為研究對象，施以時效熱處理使造成鋁合金基材顯微組織改變，然後探討此種顯微組織變化對各種刀具於不同切削條件下之磨耗情形並對刀具之磨耗機制、切削應力及加工表面之粗糙度等性質進行探討。研究結果顯示PCD刀具於各種切削條件中其刀具摩耗最低，而CBN刀具其次；其餘刀具皆會有2mm/km 以上之摩耗率不適於做有尺寸精度要求之加工。結果亦顯示切深對刀具摩耗率及表面粗糙度造成之影響最大。在本研究測試之加工條件中以PCD刀具之整體表現為最好(低摩耗率及低表面粗糙度)。
關鍵詞：金屬基複合材料、時效熱處理、磨耗率、表面粗糙度

ABSTRACT
Metal-matrix composites(MMC) have received considerable attention in recent years because of their high strength and high stiffness. These properties and the ability to operate at elevated temperatures has made these materials suitable for use in automotive and aerospace applications. Thus, many studies on the properties in metal matrix composites have been done, but most of them have focused on the fundamental mechanical properties, fatigue, abrasion and heat conduction etc. It has been established that the structure of MMCs and their fracture behavior is influenced by surface defects and hence surface finish is important.
This project investigates in what ways the tool wear mechanisms, cutting force and surface roughness of composite materials may be affected by altering the matrix microstructure of SiCp/A356 metal matrix composites.
The results showed that the Polycrystalline Diamond(PCD) tool has the lowest and the Cubic Boron Nitride(CBN) tool has the second lowest wear rate in all tested cutting conditions. The results also showed that cut depth is the most important factor that affecting the tool wear rate and surface roughness. Under all tested machining conditions, PCD tool exhibited the best overall performance with low tool wear and good surface finish.

誌謝i
中文摘要iii
英文摘要iv
目錄v
表錄ix
圖錄x
1.前言1
2.文獻回顧4
3.基本原理15
3.1.複合材料之定義15
3.2.金屬基複合材料的發展，製造與應用16
3.2.1.金屬基複合材料的發展16
3.2.2.金屬基複合材料的製造17
3.2.3.金屬基複合材料的應用18
3.3.調質理論19
3.4.析出硬化熱處理基本過程19
3.5.顆粒散佈型鋁基複合材料的強化機構21
3.6.切削理論22
3.6.1.切削工具的角度22
3.6.2.切削條件所致切屑型態的變22
3.7.鋁基複合材料之磨耗分析23
3.8. 刀具磨耗機構 24
3.9.切屑的生成機構 27
3.10.刀具材料的種類與特性28
3.10.1.碳鋼(Carbon) 29
3.10.2.高速鋼(High-Speed Steel)29
3.10.3.碳化物(Carbides) 29
3.10.4.碳化鎢(Tugsten carbide)30
3.10.5. 瓷金(Cermet)刀具 30
3.10.6.陶瓷(Ceramic)刀具 31
3.10.7.立方晶氮化硼(CBN)刀具32
3.10.8.鑽石刀具 32
3.11.切削力 33
3.11.1.切削力的測定法 33
3.11.2.切削條件與切阻力的關係33
3.12.工件加工面之粗糙 35
3.12.1.加工面粗糙度的構成35
3.12.2. 切削方向的粗糙度 35
3.12.3. 進給方向的粗糙度 36
3.12.4.加工面粗糙度的表示37
4.實驗設備與實驗方法40
4.1.實驗設備 40
4.1.1.氣氛爐 40
4.1.2.油浴爐 41
4.1.3.傳統車床 42
4.1.4.車削動力計 42
4.1.5.電荷放大器 44
4.1.6.電腦及數位類比轉換卡47
4.1.7.工具顯微鏡 49
4.1.8.光學顯微鏡 50
4.1.9.電子顯微鏡 51
4.1.10.表面蒸鍍儀 51
4.1.11.表面粗度測量儀 52
4.1.12.微硬度儀 52
4.1.13.洛氏硬度計 53
4.1.14. 車刀 54
4.1.15.工件 56
4.2.實驗方法 56
4.2.1.實驗流程 56
4.2.2.實驗規畫 57
5.結果與討論 62
5.1.各種刀具對加工表面粗糙度的影響62
5.2.刀具磨耗的探討 73
5.3.刀具產生積屑瘤對加工表面的影響84
5.4.進給對切削力的影響86
6.結論 89
7.未來的工作與展望 92
8.參考文獻 93
9.自傳 98

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