臺灣博碩士論文加值系統

在切削加工時，切削液通常提供潤滑、冷卻、及移除切屑等效用。使用微量潤滑(MQL)切削的好處不僅可大幅降低切削液的使用成本亦可符合環保議題，甚至可預期的較傳統濕式切削更有效提供潤滑及冷卻的作用。隨著對微小元件的加工需求提升，微切削加工技術也備受重視，微型工具機因此被發展而出，預期可大幅降低生產成本及節約能源損耗。採用MQL技術可較能防止濕式大量潤滑而造成微型工具機的電子零件損害。因此，本研究是針對微量潤滑在微型工具機上進行微磨削SK3工具鋼的探討，並藉由表面精度、刀具磨耗、及刀具壽命等影響做為探討依據。試圖探討微量潤滑於微磨削之加工機制。
　　研究結果顯示，在本研究中的MQL潤滑條件下，若考慮最佳的工件表面精度，建議的潤滑油流量為1.88 ml/hr及空氣流量為30 l/min。同時在實驗過程中發現，乾式磨削或純噴空氣之乾式磨削時，刀具會有斷刀的情況，且乾式磨削會有工件燒焦的狀況，而MQL磨削則無。此乃使用 MQL不僅可由潤滑效果改善磨削加工摩擦的行為，同時藉由油霧移除磨削過程所產生的切屑，進而比乾式磨削與純噴空氣之乾式磨削更能維持一定水準及較佳的表面精度。實驗結果發現MQL磨削的刀具壽命為乾式磨削的可加工面積的七倍以上。

Cutting fluids are mainly used for cooling, lubricating, and chip removing. The use of minimum/minimal quantity lubrication (MQL) in machining processes not only reduces the cost of cutting fluids but also has the potential to alleviate the environmental impact. In addition, the MQL technique could be a viable choice to decrease the damage to the miniature machines due to the near-dry lubrication. Therefore, the objective of this study is aimed at the mechanical performance of MQL for micro-grinding of SK3 steels based on surface finish and tool life.
In this study, it is observed that tool breaks in dry grinding or air blow grinding, and it is also found that workpiece surface is burned in dry grinding. However, these phenomena are not observed in MQL grinding. The reason is that the use of MQL reduces the friction between the tool and workpiece and improves the chip removal in micro-grinding. The use of MQL in micro-grinding also leads to better surface roughness and the tool life is more than seven times compared to dry grinding. Experimental results show that the best surface finish is achieved in MQL grinding when the use of cutting fluids is 1.88 ml/hr with the air flow rate of 30 l/min among the lubrication conditions in this study.

謝誌 i
目錄 ii
圖目錄 iii
表目錄 vii
摘要 viii
Abstract ix
第一章　緒論 1
1.1 研究背景與動機 1
1.2 研究目的 6
1.3 論文架構 6
第二章 文獻探討 8
2.1 切削液之功用與MQL之緣起 8
2.2 MQL之相關研究 11
第三章 實驗配置與方法 17
3.1 實驗配置 17
3.2 實驗方法 21
第四章 實驗結果與討論 29
4.1 乾式磨削與MQL磨削對工件表面精度之影響 29
4.1.1 乾式磨削與MQL磨削於不同進給之工件表面精度比較 30
4.1.2 乾式磨削與MQL磨削於不同磨削速度之工件表面精度比較 35
4.2不同潤滑條件之MQL磨削於工件表面精度及刀具磨耗的影響 42
4.3乾式磨削與純噴空氣之乾式磨削及MQL磨削之刀具壽命的比較 51
第五章 結論與未來展望 69
5.1結論 69
5.2未來展望 71
參考文獻 73
附錄：實驗設備 78

[1] S. Ebbrell, N.H. Wooley, Y.D. Tridimas, D.R. Allanson and W.B. Rowe, “The effects of cutting fluid application methods on the grinding process,” International Journal of Machine Tools and Manufacture, Vols. 40, pp. 209-223, 2000.
[2] T. Nguyen and L.C. Zhang, “An assessment of the applicability of cold air and oil mist in surface grinding,” Journal of Materials Processing Technology, Vols. 140, pp. 224-230, 2003.
[3] G. T. Smith, Advanced Machining: The Handbook of Cutting Technology, Springer-Verlag, London, 1989.
[4] M. Rahman, A. Senthil Kumar, and M. U. Salam, “Experimental evaluation on the effect of minimal quantities of lubricant in milling,” International Journal of Machine Tools and Manufacture, Vols. 42, pp. 539-547, 2002.
[5] R. D. Monici, E. C. Bianchi, R. E. Catai, and P. R. de Aguiar, “Analysis of the different forms of application and types of cutting fluid used in plunge cylindrical grinding using conventional and superabrasive CBN grinding wheels,” International Journal of Machine Tools and Manufacture, Vols. 46, pp. 122-131, 2006.
[6] F. C. Gift, “Fluid Performance Study for Groove Grinding a Nickel-Based Superalloy Using Electroplated Cubic Boron Nitride (CBN) Grinding Wheels,” Journal of Manufacturing Science and Engineering, Vols. 126, pp. 451-458, 2004.
[7] P. S. Sreejith and B. K. A. Ngoi, “Dry machining: Machining of the fucture” Journal of Materials Processing Technology, Vols. 101, pp. 287-291, 2000.
[8] F. Klocke and G. Eisenblatter, “Dry Cutting,” Annals of the CIRP- Manufacturing Technology, Vols. 46, pp. 519-526, 1997.
[9] S. Inoue and T. Aoyama, “Application of Air Cooling Technology and Minimum Quantity Lubrication to Relief Grinding of Cutting Tools,” Key Engineering Materials, Vols. 257-258, pp.345-350, 2004.
[10] L. R. da Silva, E. C. Bianchi, R. Y. Fusse, R. E. Catai, T. V. França, and P. R. Aguiar, “Analysis of surface integrity for minimum quantity lubricant-MQL in grinding,” International Journal of Machine Tools and Manufacture, Vols. 47, pp.412-418, 2007.
[11] L.R. da Silva, E.C. Bianchi, R.E. Catai, R.Y. Fusse, T.V. França, and P.R. Aguiar, “Study on the Behavior of the Minimum Quantity Lubricant-MQL Technique Under Different Lubricating and Cooling Conditions When Grinding ABNT 4340 Steel,” Journal of the Brazilian Society of Mechanical Sciences and Engineering, Vols. 27, pp. 192-199, 2005.
[12] K. Weinert, I. Inasaki, J.W. Sutherland, and T. Wakabayashi,Dry machining and minimum quantity lubrication, Annals of the CIRP Manufacturing Technology, Vols. 53, pp. 511-537, 2004.
[13] Y. Okazaki, N. Mishima, and K. Ashida, “Microfactory and Micro Machine Tools,” The 1st Korea–Japan Conference on Positioning Technology, Daejeon, Korea, pp. 1/6–6/6, 2002.
[14] G. Byrne, D. Dornfeld, and B. Denkena, “Advancing Cutting Technology,” Annals of the CIRP Manufacturing Technology, Vols. 52, pp. 483-407, 2003.
[15] M. B. G. Jun, S. S. Joshi, R. E. DeVor, and S. G. Kapoor, “An Experimental Evaluation of an Atomization-Based Cutting Fluid Application System for Micromachining,” Journal of Manufacturing Science and Engineering, Vols. 130, pp. (031118)1/8-8/8, 2008.
[16] S. Kalpakjian著, 邱雲堯, 陳佳萬, 張安欣, 鄭偉盛, 陳木榮, 何世偉, 喻立信等譯, 機械製造, 文京圖書,台北, 1998。
[17] M.C. Shaw, Metal Cutting Principles, 2nd ed., Oxford, New York, 2005.
[18] A. Attanasio, M. Gelfi, C. Giardini, and C. Remino, “Minimal quantity lubrication in turning: Effect on tool wear,” Wear, Vols. 260, pp.333-238, 2006.
[19] A.S. Varadarajan, P.K. Philip, and B. Ramamoorthy, “Investigations on hard turning with minimal cutting fluid application (HTMF) and its comparison with dry and wet turning,” International Journal of Machine Tools and Manufacture, Vols. 42, pp. 193-200, 2002.
[20] N.R. Dhar, M. Kamruzzaman, and M. Ahmed, “Effect of minimum quantity lubrication (MQL) on tool wear and surface roughness in turning AISI-4340 steel,” Journal of Materials Processing Technology, Vols. 172, pp. 299-304, 2006.
[21] 林憲茂, 博士論文, 最少量潤滑(MQL)應用於NAK80模具鋼高速銑削之研究, 國立臺灣大學機械工程學研究所,台北, 2007。
[22] L.N. L. de Lacalle, C. Angulo, A. Lamikiz, and J.A. Sánchez, “Experimental and numerical investigation of the effect of spray cutting fluids in high speed milling,” Journal of Materials Processing Technology, Vols. 172, pp. 11-15, 2006.
[23] R. Heinemann, S. Hinduja, G. Barrow, and G. Petuelli, “Effect of MQL on the tool life of small twist drills in deep-hole drilling,” International Journal of Machine Tools and Manufacture, Vols. 46, pp. 1-6, 2006.
[24] 中國砂輪企業股份有限公司, 內徑研磨用鑽石及氮化硼磨棒型錄, 第一頁。
[25] S. Filiz, C. M. Conley, M. B. Wasserman, and O. B. Ozdoganlar, “An experimental investigation of micro-machinability of copper 101 using tungsten carbide micro-endmills,” International Journal of Machine Tools and Manufacture, Vols. 47, pp. 1088-1100, 2007.
[26] 佐藤 素, 渡邊忠明等著, 唐文聰譯, 切削加工技術, 全華圖書,台北, 1990。
[27] 徐仁輝著, 切削刀具學, 正文書局, 台北, 1986。
[28] 洪良徳, 陳正仁, 陳昌順, 謝壬癸, 李鈞澤, 郭柏立, 傅光華等著, 切削刀具學, 高立圖書,台北, 1997。
[29] J. A. C. Alves, U. de Barros Fernandes, C. E. da Silva Júnior, E. C. Bianchi, P. R. de Aguiar, and E. J. da Silva, “Application of the Minimum Quantity Lubrication (MQL) technique in the plunge cylindrical grinding operation,” Journal of the Brazilian Society of Mechanical Sciences and Engineering, Vols. 31, pp. 1-4, 2009.
[30] H. Isobe, K. Hara, A. Kyusojin, M. Okada, and H. Yoshihara, “Ultrasonically Assisted Grinding for Mirror Surface Finishing of Dies with Electroplated Diamond Tools,” International Journal of Precision Engineering and Manufacturing, Vols. 8, pp. 38-43, 2007.