臺灣博碩士論文加值系統

近年由於科技的不斷進步及使用環境的日益嚴苛，尤其在高溫的氧化及硫化使用條件下，傳統的金屬材料己無法完全滿足要求，而鐵鋁基合金具有絕佳的抗硫化性及氧化的特性，再加上量輕、價廉及具有較佳的比強度，可以滿足特定的要求。但隨著鐵鋁基合金材料的開發技術的提升及改良，卻也伴隨著難加工問題產生，其原因在於其具有高比強度之特性，若由傳統加工方法進行切削時，將會導致刀具的急速磨耗，造成加工成本增加。本研究採用的線切割放電加工法，則有非常傑出的表現，希能藉此一研究提供工業與學術界參考使用，以確立鐵鋁基合金的加工技術。
本研究乃藉由田口式實驗計劃法(Taguchi method)，先行規劃線切割放電加工時的重要參數(factor)，包含送線速度、脈衝時間、脈衝休止時間、伺服電壓、線張力及不同化學成份之鐵鋁基合金等六個加工參數，在每一加工參數下各設有三個水準(level)，除送線速度為兩個水準外，以探討對加工特性，諸如切削速率、表面粗糙度及槽寬擴大量等的影響關係。藉由變異數分析（ANOVA）的推算，分別找尋獲致最大的切削速率、最低的表面粗糙度、最窄的槽寬擴大量等的最佳參數組合條件。並將所有實驗數據，經統計分析進行非線性迴歸分析，以得到經驗公式，並針對多重目標製程品質加工特性尋求最適化加工參數組合條件；最後，探討加工參數與線切割放電加工特性間的關係與加工表面層的完整性（Surface Integrity）。

The Fe-Al based alloy offers excellent characteristics of unoxidation, unsulfur, lightweight, cheap and strength that can be satisfied in special working condition.
It usually causes dramatic wear and cost while using traditional machining device to fabricate mechanical components, in contrast, WEDM (wire electrical discharge machining) offers an effective and rapid tool for machining. WEDM cuts the target via giant thermal energy depositing in a very short range of time thus evaporates and melts the metal particles. This new revised methodology proposed herein may also recommend to the industrial for practical applications.
The paper is studied by Taguchi method which shows six factors of WEDM parameters, including wire speed, pulse duration, pulse off time, servo voltage, wire tension, and alloy component. Each parameter has three levels except wire speed that has two levels. In this study that proposed to research machining characteristics of cutting speed, surface roughness, and overcut. Furthermore, an analysis of variance (ANOVA) can obtain the optimal combination of process parameters that contain of max-cutting, min-surface roughness and min-overcut. These empirical formulas are constructed by using a nonlinear regression expression which is included all the experimental data. The multi-quality evaluation is also mentioned in this paper. In addition, correlations between the parameters for machining and either the characteristics or the surface integrity of the specific material are also discussed in this study.

目 錄
誌謝...........................................................i
摘要..........................................................ii
ABSTRACT.....................................................iii
目錄..........................................................iv
表錄........................................................viii
圖錄..........................................................ix
符號說明......................................................xi
1.緒論.........................................................1
1.1研究動機....................................................1
1.2研究之目的及方法............................................2
2.基本原理.....................................................4
2.1鐵鋁基合金材料..............................................4
2.1.1鐵鋁基合金材料之發展......................................4
2.1.2鐵鋁基合金材料之製程......................................4
2.1.3鐵鋁基合金之結晶結構......................................6
2.1.4鐵鋁基合金材料之應用......................................9
2.2放電加工原理................................................9
2.2.1線切割放電加工機構.......................................12
2.2.2線切割放電加工參數.......................................15
2.2.3線切割放電加工特性.......................................16
2.3田口式實驗計劃法...........................................18
2.3.1參數設計（Parameter design)..............................21
2.3.2直交表...................................................21
2.3.3信號雜訊比...............................................23
2.3.4變異數及貢獻度分析.......................................24
2.4非線性回歸分析.............................................27
2.4.1迴歸分析意義.............................................27
2.4.2迴歸分析之用途...........................................27
3.實驗設備及方法..............................................28
3.1實驗材料...................................................28
3.1.1線電極...................................................28
3.1.2工件材料.................................................28
3.1.3加工液...................................................32
3.2實驗設備...................................................32
3.2.1線切割放電加工機.........................................32
3.2.2表面粗度儀...............................................32
3.2.3掃描式電子顯微鏡(SEM)....................................33
3.2.4 X光繞射儀...............................................33
3.2.5金相顯微鏡...............................................33
3.2.6維氏硬度機 (Vickers hardness)............................33
3.2.7超音波清洗機.............................................33
3.2.8原子力顯微鏡(Atomic force microscopy; AFM)...............34
3.3實驗方法...................................................39
3.3.1實驗流程(如圖3. 12)......................................39
3.3.2實驗設計.................................................40
3.3實驗步驟...................................................41
3.3.1線切割放電加工實驗.......................................41
3.3.2切削速率量測.............................................41
3.3.3表面粗糙度量測...........................................41
3.3.4槽寬擴大量量測...........................................41
3.3.5熱影響層量測.............................................42
3.3.6微硬度量測...............................................42
3.3.7 X光繞射分析.............................................42
4.結果與討論..................................................43
4.1切削速率...................................................43
4.1.1田口式實驗計劃法分析.....................................43
4.1.2加工參數對切削速率之影響.................................48
4.2表面粗糙度.................................................51
4.2.1口式實驗計劃法分析.......................................51
4.2.2加工參數對表面粗糙度之影響...............................56
4.3槽寬擴大量.................................................60
4.3.1田口式實驗計劃法分析.....................................60
4.3.2加工參數對槽寬擴大量之影響...............................65
4.4非線性迴歸分析.............................................68
4.5多重目標之製程參數最適化組合...............................72
4.6表面完整性之分析...........................................76
4.6.1微硬度量測...............................................76
4.6.2熱影響層.................................................79
4.6.3 X光繞射分析.............................................81
4.6.4掃描式電子顯微鏡X光之光譜圖及mapping.....................83
4.6.5原子力顯微鏡觀察.........................................85
5.結 論......................................................87
參考文獻......................................................89
自傳..........................................................93

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