臺灣博碩士論文加值系統

本研究係運用磁力研磨加工技術，以粉末冶金熱壓燒結法，將具有導磁性之鐵粉以及具有磨削性的氧化鋁粉(Al2O3)燒結的磁性磨粒，應用自行規劃、設計及組立之磁力研磨實驗設備與治具，設法模擬6061-T6鋁合金方管內表面之研磨過程，觀察並量測其研磨結果。
實驗是採用田口式品質工程法進行實驗規劃，針對磁場強度、磁性磨粒量、磁性磨粒粒度、磁極頭轉速、加工進給速度、振動頻率、振幅及切削液等加工參數，對於方管內表面研磨的材料去除量、加工效率及表面粗糙度等之影響進行研究與探討。找出加工最佳參數組合，並以實驗驗證之。
由最佳參數組合實驗驗證結果，得到上試片19.33 mg及下試片11.45 mg之最佳材料去除量及上試片1.91mg/min及下試片1.05mg/min之最佳加工效率；而粗糙度方面，由未加工前Ra 0.52mm、Rz(DIN) 2.8mm，經由最佳參數組合研磨，得到上試片Ra 0.09mm、Rz(DIN) 0.66mm及下試片Ra 0.15mm、Rz(DIN) 0.9mm之表面粗糙度。
此外，對於關鍵性的加工參數的磁力研磨特質，亦進行系列探討，以掌握其影響特性，提供加工條件設定參考。

A new internal magnetic-abrasive machining process of the 6061-T6 aluminum alloy rectangular tube is developed and investigated. In this study, a new finishing apparatus and auxiliary fixtures are designed and developed to simulate the internal finishing process, the magnetic abrasive particle that the finishing ability abrasive grains (Al2O3) are sintered with a ferromagnetic substance (iron powder) by hot pressed, and, the working parameters and their finishing performances are investigated and reported.
The Taguchi-Method is adopted for the experimental plan, magnetic field strength, quantity of magnetic abrasives, particle size of magnetic abrasives, rotating speed of magnetic pole, feed rate, vibration frequency, vibration amplitude and the coolant are to be used as the control parameters, internal surface finishing performances, such as the stock removal, the polishing efficiency, and the surface roughness, are studied and verified experimentally.
In the present case, by applying the optimal working conditions, a 19.33mg stock removing and 1.91mg/min optimal polishing efficiency were found, and the surface roughness was improved from Ra 0.52mm、Rz(DIN) 2.8mm to Ra 0.09mm、Rz(DIN) 0.66mm.
In this paper, the effects of some major parameters on the surface finishing performances are also clarified experimentally.

誌 謝 I
摘 要 II
ABSTRACT III
目 錄 IV
表 錄 VIII
圖 錄 IX
符 號 說 明 XII
第一章 前 言 1
第二章 文獻回顧 3
2.1 磁性磨粒之製造與準備 3
2.2 磁力研磨加工原理 5
2.3 磁力研磨法之加工應用 7
2.3.1 圓棒表面研磨 7
2.3.2 圓管內表面研磨 8
2.3.3 平面研磨 9
2.3.4 其他應用 10
第三章 實驗設備之設計與建構 15
3.1 加工構想 15
3.2 實驗設備之建置 16
3.2.1 磁場之產生 16
3.2.2 試片加工位置之控制 19
3.2.3 磁極頭之設計 19
3.2.4 振動載台 20
3.3 研磨試驗機之參數調整與控制 21
第四章 實驗方法與步驟 37
4.1 實驗設備與實驗材料 37
4.1.1 磁力研磨試驗機 37
4.1.2 熱壓燒結成形機 37
4.1.3 粉末混合機 37
4.1.4 恆溫烤箱 38
4.1.5 粉末篩選機 38
4.1.6 手動油壓機 38
4.1.7 超音波清洗機 38
4.1.8 精密電子天平 39
4.1.9 熱壓燒結模具 39
4.1.10 表面粗糙度儀 39
4.1.11 高斯計 39
4.1.12 試驗用試片 40
4.1.13 切削液 40
4.2 磁性磨粒之準備 40
4.3 實驗規劃 42
4.4 研磨前加工間隙之設定 45
4.5 模擬方管內表面研磨實驗步驟 45
4.6 材料去除率與表面粗糙度之檢測 46
4.7 方管內隅角之研磨 49
第五章 結果與討論 63
5.1 缺口型磁極頭之研磨樣式 63
5.2 參數水準組合與材料去除量 63
5.3 參數水準組合與加工效率 65
5.4 參數水準組合與表面粗糙度 67
5.5 主要加工參數對磁力研磨之影響 70
5.5.1 磁極頭轉速對研磨之影響 70
5.5.2 磁性磨粒量對研磨之影響 71
5.5.3 磁性磨粒粒度對研磨之影響 71
5.5.4 進給速率對研磨之影響 72
5.6 溶水油含水比例對磁力研磨之影響 72
5.7 方管內隅角研磨均勻性之控制 73
第六章 結論 99
第七章 建議 102
參考文獻 104
附錄一 田口式品質工程計算 108

[1] T. Shinmura, K. Takazawa, E. Hatano, “Study on Magnetic Abrasive Finishing”, Annals of the CIRP, Vol.39, No.1, pp.325-328, 1990.
[2] 方卓平，「磁力研磨法之現況和發展方向」，機械技術，148期，pp.131-137，民國八十六年六月。
[3] H.J. Ruben, A. Niku-Lari(Ed.), “Advances in Surface Treatments”, Vol.5, Pergamon Press, pp. 239-256, 1987.
[4] T. Shinmura, H. Yamaguchi, “Study on a New Internal Finishing Process by the Application of Magnetic Abrasive Machining (Internal Finishing of Stainless Steel Tube and Clean Gas Bomb)”, JSME International Journal, Series C, Vol.38, No.4, pp.798-804, 1995.
[5] T. Shinmura, F. H. Wang, “A New Process for Precision Finishing of Silicon Nitride Fine Ceramics by the Application of Magnetic Abrasive Machining Using Chromium-oxide Abrasives Mixed with Iron Particles”, Int. J. Japan Soc. Prec. Eng., Vol.28, No.3, pp. 229-230, 1994.
[6] 黃文科、郭佳儱，「燒結法製作磁性磨粒之研究」，中國機械工程學會第十八屆全國學術研討會論文集，民國九十年十二月，第219-225頁。
[7] 邱朝明、郭佳儱、吳偉堯，「放電被覆法於磁性磨粒製作之研究」，中國機械工程學會第十八屆全國學術研討會論文集，民國九十年十二月，第227-233頁。
[8] 張榮顯，「磁力研磨加工應用於放電表面改善之研究」，國立中央大學機械工程研究所碩士論文，民國九十年六月。
[9] T. Shinmura, K. Takazawa, E. Hatano, T. Aizawa, “Study on Magnetic-Abrasive Process (Process Principle and Finishing Possibility)”, Bull. Japan Soc. of Prec. Engg., Vol.19, No.1, pp.54-55, March 1985.
[10] T. Shinmura, T. Aizawa, “Study on Internal Finishing of a Non- ferromagnetic Tubing by Magnetic Abrasive Machining Process”, Bull. Japan Soc. of Prec. Engg., Vol.23, No.1, pp.37-41, March 1989.
[11] T. Shinmura, K. Takazawa, E. Hatano, T. Aizawa, “Study on Magnetic-Abrasive Process (Finishing Characteristics)”, Bull. Japan Soc. of Prec. Engg., Vol.18, No.4, pp.347-348, December 1984.
[12] T. Shinmura, K. Takazawa, E. Hatano, “Study on Magnetic -Abrasive Process (Effects of Machining Fluid on Finishing Characteristics)”, Bull. Japan Soc. Of Prec. Engg., Vol.20, No.1, pp.52-54, March 1986.
[13] T. Shinmura, K. Takazawa, E. Hatano, “Study on Magnetic -Abrasive Finishing (Effects of Various Type of Magnetic Abrasives on Finishing Characteristics)”, Bull. Japan Soc. of Prec. Engg., Vol.21, No.2, pp.139-141, June 1987.
[14] M. Fox, K. Agrawal, T. Shinmura, R. Komanduri, ” Magnetic Abrasive Finishing of Rollers”, Annals of the CIRP, Vol.43, pp.181-184, 1994.
[15] T. Shinmura, “Development of a Unit System Magnetic Abrasive Finishing Apparatus using Permanent Magnets”, Bull. Japan Soc. of Prec. Engg., Vol.23, No.4, pp.313-315, December 1989.
[16] T. Shinmura, H. Yamaguchi, Y. Shinbo, “A New Internal Finishing Process of a Non-ferromagnetic Tubing by Applying a Rotating Magnetic Field”, Int. J. Japan Soc. Prec. Eng., Vol.26, No.4, pp.302-304, December 1992.
[17] T. Shinmura, H. Yamaguchi, “Study on a New Internal Finishing Process of a Nonferromagnetic Tube by the Application of a Linearly Traveling Magnetic Field (On the Process Principle and the Behaviors of Magnetic Finishing Tool)”, Int. J. Japan Soc. Prec. Eng., Vol.28, No.1, pp.29-34, March 1994.
[18] H. Yamaguchi, T. Shinmura, T. Kaneko, “A New Internal Finishing Process by Applying Magnetic Abrasive Finishing through the Use of the Pole Rotation System (Processing Principle with a Few Finishing Characteristics)”, Int. J. Japan Soc. Prec. Eng., Vol.29, No.4, pp.29-34, December 1995.
[19] H. Yamaguchi, T. Shinmura, T. Kaneko, “Development of a New Internal Finishing Process Applying Magnetic Abrasive Finishing by Use of Pole Rotation System”, Int. J. Japan Soc. Prec. Eng., Vol.30, No.4, pp.317-322, December 1996.
[20] H. Yamaguchi, T. Shinmura, “Study of the surface modification resulting from an internal magnetic abrasive finishing process”, WEAR, Vol.225-229, pp. 246-255, 1999.
[21] T. Shinmura, K. Takazawa, E. Hatano, “Study on Magnetic -Abrasive Process (Application to Plane finishing)”, Bull. Japan Soc. of Prec. Engg. Vol.19, No.4, pp.289-291, 1985.
[22] T. Shinmura, T. Aizawa, “Study on Magnetic Abrasive Finishing Process (Development of Plane Finishing Apparatus using a Stationary Type Electromagnet)”, Bull. JAPAN Soc. of Prec. Engg. Vol.23, No.3, pp.236-239, 1989.
[23] T. Shinmura, F. H. Wang, T. Aizawa, “Study on a New Finishing Process of Fine Ceramics by Magnetic Abrasive Machining (On the Improving Effects of Finishing Efficiency Obtained by Mixing Diamond Magnetic Abrasives with Ferromagnetic Particles)”, Int. J. Japan Soc. Prec. Eng., Vol.28, No.2, pp.99-104, 1994.
[24] T. Shinmura, K. Takazawa, E. Hatano, “Study on Magnetic -Abrasive Process (Application to Edge Finishing)”, Bull. Japan Soc. of Prec. Engg., Vol.19, No.3, pp. 218-220, 1985.
[25] J.D. Kim, Y.H. Kang, Y.H. Bae, S.W. Lee, “Development of a magnetic abrasive jet machining system for precision internal polishing of circular tubes”, Journal of Materials Processing Technology, Vol.71, pp.384-393, 1997.
[26] 黃孟祥，「磁氣研磨法於微細電極表面拋光技術之研究」，國立雲林科技大學機械工程技術研究所碩士論文，民國八十九年六月。
[27] 白中和編譯，”圖解電磁學原理與應用”，建興出版社，1998。
[28] 鍾清章，田口式品質工程導論，中華民國品質學會，民國八十七年元月。
[29] 鍾清章等，品質工程(田口方法)，中華民國品質學會，民國八十七年九月。
[30] 經濟部標準檢驗局，表面粗糙度，經濟部標準檢驗局標準總號7868，標準類號B10272，民國七十年九月二十四日公布。