臺灣博碩士論文加值系統

本論文之主旨在於應用超音波輔助撓性夾具車削。首先利用電腦輔助設計和有限元素法進行模擬分析，設計完成後以線切加工製作尺寸精度高之撓性刀具座，再設計一平台固定刀具座並連結超音波振盪器來達到撓性振動切削的效果。
車削實驗結果顯示，加入振動之撓性刀具座除了進給0.04mm/rev以下，其餘切削條件皆優於剛性車削。粗糙度改善率隨著進給增加平均可達8.29%，最高可達27.35%；進給切削力改善率平均為23.4%，最高可達73%；垂直切削力改善率平均為28%，最高可達55.6%。

The purpose of this thesis is to develop the effect of ultrasonic-assited turing by using a flexible fixture to the machining of aluminum alloys compared with traditional fixture. At first , the computer-aided design and finite element method is used to analyze it’s structural property. Second, we use electric discharge wire-cut machining to make high-precision flexible fixture. Finally, we design the plane for turning by using flexible fixture which is connect with an oscillator for the purpose of vibratory machining.
The experiment results show the surface roughness of workpiece is improved by using ultrasonic-assited flexible fixture except when the feed is less than 0.04mm/rev;the horizontal force and the vertical force reduce averagely 28% and 23.4%,respectively.

目錄

摘要 II
ABSTRACT III
目錄 IV
表目錄 VII
圖目錄 IX
1-1 前言 1
1-2 文獻回顧 1
1-2-1 撓性夾具理論 1
1-2-2 超音波輔助車削 3
1-3 研究動機與目的 5
第二章 實驗流程與相關理論 6
2-1 實驗流程 6
2-2 有限元素法 6
2-3 直交表實驗歸劃法 8
2-4 反應曲面法 10
2-5 表面粗糙度 12
2-6振動輔助車削原理與應用 14
2-6-1切削中的振動與振顫 14
2-6-2 振動切削原理 15
2-6-3 磁致伸縮材料與超音波震盪器 15
第三章 撓性夾具之設計與分析 17
3-1 撓性夾具設計理念 17
3-2 撓性夾具分析 20
3-2-1分析過程 20
3-3 振動輔助撓性夾具車削之概念設計 26
第四章 實驗設備與實驗規劃 27
4-1 實驗設備 27
4-1-1 CNC車床 27
4-1-2 切削刀具與材料 29
4-1-3 三軸向微動力計 30
4-1-4 聲波放大器與超音波震盪器 31
4-1-5 表面粗糙度儀 32
4-2 實驗規劃 33
第五章 實驗結果與分析 38
5-1 車削實驗結果 38
5-1-1剛性夾具與撓性夾具實驗結果 38
5-1-2振動輔助撓性夾具實驗結果 40
5-2 粗糙度實驗結果統計資料分析 45
5-2-1 統計檢定 45
5-2-2 表面粗糙度迴歸關係圖 49
5-3-1切削力實驗結果 58
5-3-2進給方向(Fy)切削力量測 59
5-3-3垂直方向(Fz)切削力量測 62
5-3-4 切削力與表面粗糙度迴歸關係圖 64
第六章 結論與未來展望 66
6-1 結論 66
6-2 未來展望 66
參考文獻 67

[1] Daryl L. Logan, A First Course in the Finite Element Method, third edition, Brooks/Cole, 2002.
[2] Bow, G. E. P. and Wilson, K. B., “On the experimental attainment of optimum conditions”. Journal of the Royal Statistic Society, B13, 1-38, discussion: 38-45, 1951.
[3] Schotborgh Wouter O., Kokkeler Frans G.M., Tragter Hans, and Van Houten Fred J.A.M., “Dimensionless Design Graphs for Flexure Elements and a Comparison between Three Flexure Elements”, Precision Engineering, 29, pp.41-47, 2005.
[4] Zhu, Wen Hong, Jun, Martin B., and Yusuf Altintas, “A Fast Tool Servo Design for Precision Turning of Shafts on Conventional CNC Lathes”, International Journal of machine Tool & Manufacture, Vol.41, pp. 953~965, 2001.
[5] Elfizy, A.T., Bone, G.M., and Elbestawi, M.A., “Design and Control of a Dual-Stage Feed Drive”, International Journal of Machine Tools & Manufacture, Vol. 45, pp. 153~165, 2005.
[6] 賴昆輝，「撓性車削系統之微精細車削特性研究」，國立台灣海洋大學，碩士論文，民國94年。
[7] 孔永祥，「撓性車削之加工精度探討」，國立台灣海洋大學，碩士論文，民國94年。
[8] 楊雅量，「微性夾具用於精車削之研究」，國立台灣海洋大學，碩士論文，民國95年。
[9] 謝宗育，「振動輔助撓性夾具系統應用於微車削之研究」，國立台灣海洋大學，碩士論文，民國96年。
[10] 葉榮律，「撓性刀具之切削力學分析」，國立台灣海洋大學，碩士論文，民國97年。
[11] 李昱辰，「撓性夾具對於車削加工性能之影響研究」，國立台灣海洋大學，碩士論文，民國97年。
[12] 黃大肇，「撓性夾具之剛性對於車削加工之影響」，國立台灣海洋大學，碩士論文，民國97年。
[13] 陳杰、田光學，「超音波振動乾式車削尺寸精度實驗研究」，中國工程物理研究院，工具技術第42卷，2008年。
[14] 楊曉明、趙?、王寶榮，「振動切削技術特點及其應用狀況」，機械第35卷，2008年。
[15] 鄭振東，超音波工程，全華科技圖書股份有限公司，民國88年。
[16] Horst Weber, Jurgen Herberger, Rolf Pilz, “truning of machinable
glass ceramics with an ultrasonically viberated tool”, Annals of the
CIRP, Vol. 33, No. 1, 1984, pp. 85-87
[17] V. K. Astashev, ” Effect of Ultrasonic Vibration of A Single-Point Tool on The Process of Cutting ,” Journal of Machinery Manufacture, No. 5, pp.65-70.
[18] A. I. Isaev, V S. Anokhin, “The Use of Ultrasonic Vibration of A Tool in The Course of Cutting Metals”, Vestnik Mashinostroeniya, No. 5, pp. 56-62, 1961.
[19] L. J. Wang, J. Zhao, “Influence on Surface Roughness in Turning With Ultrasonic Vibration Tool”, Mach. Tools Manufact., Vol. 27, No. 2, pp. 181-190, 1987.
[20] T. Moriwaki, E. Shamoto, “Ultraprecision Diamond Turning of
Stainless Steel by Applying Ultrasonic Vibration”, Annals of The CIRP, Vol40/1, pp. 559-562, 1992.
[21] G. F. Gao, B. Zhao, F. Jiao, C. S. Liu, “Research on The Influence of The Cutting Conditions on The Surface Microstructure of Ultra-thin Wall Part in Ultrasonic Vibration Cutting”, Journal of Materials
Processing Technology, Vol.129, pp. 66-70, 2002.
[22] Takeyama, H., Iojoma, N., “Machinability of glassfiber reinforced
plastics and application of ultrasonic machinging”, Annals of the CIRP, Vol. 37, No. 1, 1988.
[23] Moriwaki T. and Shamoto E., K.,“Ultra-precision diamond turning of stainless steel by applying ultrasonic vibration”, JSPE, Vol. 57, No. 11,
pp.1983-1988, 1991.
[24]李輝煌，田口方法-品質設計的原理與實務，高立圖書有限公司，2003。
[25] Zhang Shilong and Fasse Ernest D., “A Finite-Element-Based Method to Determine the Spatial Stiffness Properties of a Notch Hinge”, Journal of Mechanical Design, 123, pp.141-147, 2001.
[26]Zhu, Wen Hong, Jun, Martin B., and Yusuf Altintas, “A Fast Tool Servo Design for Precision Turning of Shafts on Conventional CNC Lathes”, International Journal of machine Tool & Manufacture, Vol.41, pp. 953~965, 2001.
[27]Fuh, Kuang Hua, Chao, Jung Hui, and Wang, Jing Xing, “Design Manufacture and Analysis of Precision Flexible Fixture with Mill-Polishing System”, The 3nd Conference on Precision Machinery and Manufacturing Technology, pp. 85~94, 2005.
[28]Tak, Yoshimi, Sawada, Kiyoshi and Sata, Toshio, “Computer Aided Ultra-Precision Micro-Machining of Metallic Materials”, International on Conference on Robotics and Automation/IEEE, pp. 62~72, 1995.
[29]Woronko, Andrew, Huang, Jin, Altintas, Yusuf, “Piezoelectric Tool Actuator for Precision Machining on Conventional CNC Turning Centers”, Precision Engineering, 27 pp. 335~345, 2003.
[30]Kim, Jeong Du and Kim, Dong Sik, “Development of A Combined-Type Tool Dynamometer with a Piezo-film Accelerometer for an Ultra-Precision lathe”, Journal of Materials Processing Technology, Vol. 71, pp. 360~366, 1997.
[31]Elfizy, A.T., Bone, G.M., and Elbestawi, M.A., “Design and Control of a Dual-Stage Feed Drive”, International Journal of Machine Tools & Manufacture, Vol. 45, pp. 153~165, 2005.