臺灣博碩士論文加值系統

“表面粗糙度”、“刀具壽命”及“切削力”乃現今電腦數值控制(CNC)切削工業常追求之目標，本研究選定ECOCA-3807數值控制車床，針對不同刀具與材料之各項切削作業，在多重目標考量下，以田口實驗方法，選擇容納四個因子（切深、進給、轉速、刀尖中心度）三個水準（低、中、高）的 直交表；並配合加工環境差異，導入三個因子（頂心、切削液、刀具伸長量）的 外直交表，以分析所建立之實驗。
本研究先選定“表面粗糙度”為品質特性進行實驗，以MITSUTOYO SURFTEST 表面粗度儀量測切削結果之表面粗糙度，藉由田口分析技巧建立第一組最適切削條件；再以“刀具壽命”為品質特性進行實驗，藉由SONY COLOR VIDEO電子影像顯微鏡檢測刀具之磨耗，分析並建立第二組最適切削條件；最後，在上述兩組最適切削條件之間，以“切削力” 為品質特性進行競爭式實驗，為經濟有效地分析切削力，在ECOCA-3807數值控制車床上進行反向實驗；運用電子電路學之設計原理，發展一套車削力模擬電路，進行實際車削力之模擬研究，以Visual Basic 6.0開發模擬電路之控制程式，進行實際車削力之模擬實驗；以田口實驗法，在兩組最適切削條件之間競爭，分析並尋求多目標最佳切削參數組合；進而將最佳切削參數，在數控車床上進行實際切削，以驗證表面粗糙度與刀具磨耗。
研究結果顯示，進給因子對於表面粗糙度影響顯著，轉速與切深因子對刀具磨耗度影響顯著，切深及進給因子對切削力影響顯著；並由最佳切削參數之實際切削結果驗證，本競爭模式之最佳參數組合的確可達成令人滿意之品質特性。

Surface roughness, tool life, and cutting force are considered as major objectives in the modern CNC (computerized numerical control) machining industry. This Study thesis is proposed to experimentally perform various turning operations with different cutting tools on an ECOCA-3807 CNC lathe under the concerns of multiple objectives. The Taguchi method is commenced through selection of orthogonal array for four machining parameters (cutting depth, feed rate, spindle speed, and tool runoff) with three different levels (low, medium, and high). Additionally, a three-parameter (back centering, coolant, and tool extension) environmental orthogonal array is also introduced for the deviations between experiment and real industry to analyze the established experiment.
The surface roughness is primarily selected as the quality characteristic for the machining experiment, and the MITSUTOYO SURFTEST is utilized to evaluate the surface roughness of machined work pieces. Through the analytical practice of Taguchi method, the first set of optimum cutting conditions is received. Additionally, the tool life is then considered as the second quality characteristic, and the SONY COLOR VIDEO electronic microscope is applied to scale the tool wear. Therefore, the second set of optimum cutting conditions is derived through the analytical technique of Taguchi method. Moreover, the cutting force is considered as the third quality characteristic to be competitively challenged between the two sets of optimum conditions. Based on the electronics circuit developed in the previous Study thesis（NSC93-2212-E-237-007）, the control program by Visual Basic 6.0 is moreover commenced for the cutting force simulation. The Taguchi method is employed for the competition between two sets of optimum conditions. The optimum cutting parameters are thus achieved through the proposed competition technique. Furthermore, this Study thesis proposes to exam the surface roughness and tool wear under the optimum cutting parameters on the CNC lathe, as well as the cutting force through the KISTLER type 9001 force sensor under the tool base.
According to research, the feed rate factors reveal obvious influence on the surface roughness, the spindle speed and cutting depth factors reveal obvious influence on the tool wear and cutting depth and feed rate factors reveal obvious influence on the cutting force. By the best cuts of the parameter the actual cutting result confirmation. The best parameter combination of this competition mode can reach to the satisfied quality.

英文摘要………………………………………………………………i
中文摘要………………………………………………………………iii
目錄……………………………………………………………………iv
第一章 緒論……………………………………………………………1
1.1 研究動機與目的……………………………………………1
1.2 文獻回顧……………………………………………………3
1.3 研究方法……………………………………………………4
1.4 貢獻與價值…………………………………………………5
第二章 理論背景………………………………………………………8
2.1 品質特性……………………………………………………6
2.1.1 表面粗糙度……………………………………………6
2.1.2 刀具壽命………………………………………………9
2.1.3 車削力數學模式……………………………………11
2.2 切削參數……………………………………………………13
2.2.1 切削速度………………………………………………13
2.2.2 進給量…………………………………………………13
2.2.3 切削深度………………………………………………14
2.2.4 刀尖中心度……………………………………………14
2.3 環境因素……………………………………………………14
2.3.1 切削液…………………………………………………14
2.3.2 頂心……………………………………………………16
2.3.3 刀柄伸長………………………………………………16
2.4 競爭式最佳化………………………………………………16
第三章 實驗方法………………………………………………………17
3.1 田口實驗計畫法……………………………………………18
3.1.1 田口實驗計畫法………………………………………21
3.1.2 競爭式多目標法………………………………………27
3.2 研究進行步驟………………………………………………29
第四章 切削力模擬……………………………………………………33
4.1 反向實驗設計………………………………………………33
4.2 電子電路模擬系統之開發…………………………………37
4.3 模擬系統驗證………………………………………………41
第五章 實驗設備與過程………………………………………………43
5.1 加工性能最佳化切削實驗設備……………………………43
5.1.1 工具機…………………………………………………44
5.1.2 實驗材質………………………………………………44
5.1.3 刀具選用………………………………………………44
5.1.4 表面粗度儀……………………………………………45
5.1.5 電子影像顯微鏡………………………………………46
5.1.6 扭力扳手………………………………………………46
5.1.7 光源產生器……………………………………………46
5-2 實驗條件與規劃……………………………………………47
5-3 實驗步驟……………………………………………………49
5-4 量測方法……………………………………………………53
第六章 實驗結果與討論………………………………………………56
6.1 表面粗糙量測結果…………………………………………56
6.1.1 細切削實驗-表面粗糙量測結果……………………56
6.1.2 精密切削實驗-表面粗糙量測結果…………………62
6.2、刀具磨耗結果…………………………………………………67
6.2.1 細切削實驗-刀具磨耗結果……………………………67
6.2.2 精密切削實驗-刀具磨耗結果…………………………70
6.3 模擬切削力結果………………………………………………73
6.3.1 細切削實驗-模擬切削力結果…………………………73
6.3.2 精密切削實驗-模擬切削力結果………………………75
6.3.3 競爭式最適參數選用定義……………………………77
6.4 最適切削參數驗證……………………………………………78
6.4.1 細切削最適切削參數驗證……………………………78
6.4.2 精密切削最適切削參數驗證…………………………87
第七章 結論………………………………………………………… 91
參考文獻………………………………………………………………92
作者簡歷…………………………………………………………………94

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