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研究生:呂學傑
研究生(外文):Syue-Jie Lu
論文名稱:以加工參數抑制裂紋生成法改善放電加工表面之疲勞壽命
論文名稱(外文):Improvement of Fatigue Life by Reducing the Formation of Crack during EDM Process
指導教授:戴子堯戴子堯引用關係
指導教授(外文):Tzu-Yao Tai
學位類別:碩士
校院名稱:南台科技大學
系所名稱:機械工程系
學門:工程學門
學類:機械工程學類
論文種類:學術論文
論文出版年:2007
畢業學年度:95
語文別:中文
論文頁數:80
中文關鍵詞:放電加工表面裂紋疲勞壽命
外文關鍵詞:EDMsurface crackfatigue life
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放電加工由於不受工件材料之硬度、強度等之限制,凡能導電的材料均能做放電加工,但加工表面會有一層變質層產生,不僅提高材料表面粗糙度,且具有空孔、裂紋,引入應力等等缺陷,而放電加工後工件,常常也需被應用於高溫、高壓或必須承受疲勞環境場合中,因此本研究將針對如何降低放電裂紋的生成以提高疲勞壽命進行探討。
本實驗將以加工參數來抑制裂紋之生成,進而改善放電加工表面之疲勞壽命,選用材料是以SKD11工具鋼,放電加工參數為4A、16μs(有裂紋生成),16A、4μs(白層薄無裂紋生成)與32A、16μs(白層厚無裂紋生成),進行放電加工,放電後試片進行疲勞試驗,其疲勞負荷設定為245kg、215kg、185kg、150kg,應力比R=0.1。試件分別為有裂紋生成試件、白層較厚無裂紋生成試件、白層較薄無裂紋生成試件與拋光試件,進行疲勞測試加以觀察疲勞壽命,並做疲勞斷口形貌、表面粗糙度量測、再鑄層顯微分析、變質層硬度量測與表面形貌等表層特性觀察,以了解放電加工與表層特性之關連性。
研究結果顯示,改變放電加工參數,提高放電電流與降低其放電持續時間,能有效抑制裂紋生成並提升疲勞壽命。白層厚度的增加會提升其脆性,更降低其材料延性,加快裂紋在此層間之擴展速,進而達到失效破壞,降低其疲勞壽命。而粗糙度由於相差不大,在疲勞壽命的影響上,裂紋的存在之效應大於表面粗糙度。使用不同加工試件中,其疲勞壽命最好依次分別為拋光試件、白層較薄無裂紋生成試件、白層較厚無裂紋生成試件、有裂紋生成試件。實驗結果說明以加工參數抑制裂紋生成法,可有效抑制放電加工表面裂紋生成,以加工參數抑制裂紋生成法可提升疲勞強度與疲勞壽命,進而改善放電加工品質。
EDM process the unrestricted of workpiece materials with hardness and strength properties, electric conductivity material can made EDMed process, process surface have one recasting layer produce , not merely raise the roughness of material surface, and have empty hole, cracks, introduce such defects as the residual stress, EDMed workpiece after processing, it is apply into high temperature, high pressure or must bear fatigue environmental occasion to need too often, so this to how research is it discharge formulation reduce of cracks and increase fatigue life to the discussion .
The Experiment to improvement fatigue life by reducing the formation of crack during EDMed process, it is with the tool steel of SKD11 to select materials for use, it is in the pulse current for 4A, 16A, 32A and plse-on duration for 16μs, 4μs , EDM processing, workpiece go on fatigue test after EDMed, its fatigue loading force is set up for 245kg, 215kg, 185kg, 150kg, stress ratio to R =0.1, workpieces of respectively for having cracks to produce, The white layer compare thickness is no cracks to produce workpiece ,The white layer compare thinness is no cracks to produce workpiece and polishing workpice , carry on the fatigue testing and observe fatigue life, moreover make fatigue broken topography , surface roughness to measurement , recasting layer to analysis ,recasting layer of hardness measurement and surface topography to examine with surface shape property.Understands the EDMed and surface layer characteristic of correlational.
The results revealed that changes EDMed to process the parameters, improvement the pulse current and reducing pulse-on duration , Can suppress effect of effectively the cracks production. White level thickness increases promotes its brittleness, reduces its material ductility, Speeds up the cracks to expand in this fast, then achieves the expiration to failure, reduces its fatigue life.In because the experiment roughness difference is not big, in fatigue life's influence, the cracks effect of existence is bigger than the surface roughness. Use in the different processing test specimens , its fatigue life is best respectively be the polished workpiece,The white layer compare thinness is no cracks to produce workpiece , The white layer compare thickness is no cracks to produce workpiece, has the cracks to produce the test workpiece.The experimental results revealed that processes the parameter to reducing the formation of cracks method, but suppresses the EDMed surface cracks production effectively, processes the parameter to suppress the crack formation method to be possible to improvement the fatigue strength and the fatigue life, then improvement EDMed quality.
中文摘要………………………………………………………………………….…...I
英文摘要………………………………………………………………………….…..II
誌謝……………………..…………………………………………………...……III
總目錄…………………….………………………………………………………….IV
表目錄………………….…………………………………………..…………….….VI
圖目綠……………………….………………………………………………..…….VII
第一章、緒論…………………………….…………………..…………………..……1
1.1前言…………………………….…………………………………..………….1
1.2研究動機………………………………………………………………..……..2
第二章、文獻回顧………………………………………………..…………………4
第三章、理論說明…………………………………………………….…………...10
3.1 放電加工原理……………………………………………………..………..10
3.1.1 放電加工之過程………………………………………………..…….12
3.1.2 加工參數………………………………………………………………13
3.1.3 放電加工之優缺點……………………………………………………..14
3.1.4 放電加工之表面形貌……………………………………..…………..16
3.1.5 變質層特微……………………………………………………………20
3.1.6 變質層的硬度變化……………………………………………….…..21
3.1.7放電加工之殘留應力……………………………………………….…22
3.2 疲勞理論……………………………………………………………………..23
3.2.1 S-N曲線……………………………………………….………………..23
3.2.2疲勞裂紋的起始與成長………………………………………………25
3.2.3 裂紋分類………………………………………………………………26
第四章、實驗內容………………………………………………………………….29
4.1 實驗流程……………………………………………….………………….29
4.2 實驗材料…………………………………………………….…………….31
4.3 實驗規劃………………………………………………………….……….32
4.4 實驗儀器及設備……………………………………………………….….34
4.5 白層平均厚度計算方法…………………………………………………..41
第五章、結果………………………………………………………………………43
5.1 放電加工之表面形貌………………………………………….………….43
5.2 放電裂紋之生成……………………………………………..………..…….43
5.3 白層…..…………………………………………………………………...47
5.4 疲勞結果…..….…………………………………………………………….53
5.5 疲勞破斷面….……………………………………………………….……..56
第六章、討論………………………………………………………………………64
6.1放電裂紋對疲勞的影響………..……………………………………………64
6.2白層硬度對疲勞的影響….……………………….………………………67
6.3白層厚度對疲勞的影響….…….………………………….…………………69
6.4表面粗糙度對疲勞的影響……...……………………………………………71
第七章、結論……………………………………………………………………….73
第八章、參考文獻……………………………………………….…………………75
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