臺灣博碩士論文加值系統

本文主要目的，在於探討高速端銑削下，乾切與濕切時之各種切削現象。實驗中所使用者為碳化鎢刀具，工件之材料，則為已經過熱處理之模具鋼SKD11(HRC 60)。所探討加工現象包括，在不同切削參數(切速和每齒進給)下，乾切和濕切時的平均切削合力、刀具磨耗、表面精度、切屑變化，以及刀腹及凹坑磨耗面上之黏著層等。
實驗結果發現，在乾銑削加工下，當進行低速切削時，其切削溫度已超過SKD11的二次硬化溫度，因此，隨著切削速度的增加，平均切削合力呈現下降現象，此時所產生之切屑在橫寬面上有鋸齒狀形成。當切削速度提升至中速時，平均切削合力降至最低，且在刀腹和凹坑之磨耗面上，因擴散作用形成一複合碳化物之黏著層，經過DEAX分析，其成分包括Fe、V、Cr等；此外，在中速切削時，可以找到一適當之每齒進給範圍，使刀具磨耗量最低。在切屑橫寬面上之鋸齒現象逐漸消失。至於高速乾銑削時，切削溫度超過碳化鎢刀具的紅熱硬度，使得刀具磨耗嚴重，平均切削合力上升﹐切屑橫寬面上現鋸齒狀又再次出現。
濕銑削加工下，當切削速度由低速提升至中速時，平均切削合力先下降後上升再下降﹔在高速時，由於切削液不易流入切削區，使得刀具磨耗嚴重，平均切削合力上升；而在濕切情況下，刀腹和凹坑之磨耗面上並未形成顯著之黏著層。此外，比較乾切和濕切時發現，在中速低進給以及高速切削時，採用濕切，可以顯著減少刀腹磨耗。在切屑型式的變化上，濕切時增加每齒進給下，在切屑寬度上的鋸齒狀愈明顯。

The purpose of the study is to investigate the machining phenomena of high speed end-milling in both dry and wet cutting conditions. The cutting tool used in the experiments is a carbide tool; the working material is the die steel SKD11 (HRC60). The main issues discussed are as follows: the cutting force under dry and wet cutting with different machining parameters (i.e. different cutting speeds or feeds per tooth…etc), the tool wear, the surface roughness of the finished work piece, the shape of the chips, and the sticking layer on the flank and the crater surface of the tool.
Through experiments, it is found that, under the dry cutting conditions at the low cutting speed(56.66 m/min), the cutting temperature of the SKD11 will be higher than its secondary hardening temperature. Therefore, with the increase of the cutting speed, the cutting force will decrease correspondingly; besides, the chips produced herewith will demonstrate a saw-tooth profile over their longitude section. When the speed is raised to the medium speed(197.92 m/min), the cutting force will reach its lowest value, and there will be a sticking layer of complex carbides, caused by diffusion, on the wear surface of the flank and the crater of the tool. The EDAX analysis shows that the sticking layer is composed of Fe, V, Cr. Furthermore, according to the experiments, it is possible to find a specific rage of the feed per tooth which can lower down the amount of the tool wear to minimum. In the mean time, the saw-tooth profile along chips’ longitude section, will gradually diminish. When the cutting speed in the dry cutting is raised to “high speed” (226.19 m/min), the cutting temperature will be above the red-hardness of carbide tool, which will result in severe worn-out of the machining tool. The cutting force will increase and the saw-tooth profile along chips’ longitude section will show up again.
In the wet cutting, when the cutting speed is raised from “medium speed” to “high speed”, the cutting force will increase first and then decrease. In high-speed machining, because it is not easy for the cutting fluid to flow into the cutting zone, the cutting force will increase, which makes the worn-out of the tool become more severe. In the wet cutting, there is no significant sticking layer produced on the flank and the crater surface of the tool. When comparing the wet cutting with the dry cutting, it is found that the flank wear will decrease under two conditions: wet cutting at high speed and the low feed at medium speed. In terms of the profile along chips’ longitude section, it will become obvious in wet cutting when the feed per tooth is increased.

誌謝 ................................一
中文摘要 ................................二
英文摘要 ................................三
目錄 ................................五
圖目錄 ................................七
表目錄 ................................十二
第一章 導論..............................1
1-1研究動機............................1
1-2文獻回顧............................3
1-3本文目的............................7
1-4本文內容............................8
第二章 相關理論..........................9
2-1高速切削加工........................9
2-1-1高速切削起源....................9
2-1-2高速切削發展過程................10
2-1-3高速切削的定義及特性............13
2-1-4高速切削的應用範圍..............15
2-1-5高速主軸簡介....................15
2-2模具鋼SKD11的用途和冶金性質.........16
2-3刀具材料性質介紹....................22
2-4切削理論............................24
2-4-1切屑之形成與分類..................24
2-4-2切削力學..........................27
2-5磨耗理論............................33
2-6切削液..............................37
第三章 實驗設備與方法....................40
3-1實驗設備............................40
3-2實驗方法............................43
3-3實驗上銑削條件之計算................46
第四章 實驗結果與討論....................47
4-1乾銑削部分..........................47
4-1-1平均切削合力與切削速度關係......47
4-1-2平均切削合力與每齒進給量關係....47
4-1-3刀具磨耗與切削速度關係..........48
4-1-4刀具磨耗與每齒進給量關係........54
4-1-5表面粗糙度與切削速度關係........55
4-1-6表面粗糙度與每齒進給量關係......56
4-1-7綜合討論........................57
4-2濕銑削部分..........................68
4-2-1平均切削合力與切削速度關係......68
4-2-2平均切削合力與每齒進給量關係....68
4-2-3刀具磨耗與切削速度關係..........69
4-2-4刀具磨耗與每齒進給量關係........75
4-2-5表面粗糙度與切削速度關係........76
4-2-6表面粗糙度與每齒進給量關係......77
4-2-7綜合討論........................78
第五章 結論與建議........................84
附錄.....................................87
參考文獻.................................93
作者簡介.................................99

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