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研究生:鄭耀鴻
研究生(外文):Yao-Hung Zheng
論文名稱:精微銑削SKD61模具鋼之微小端銑刀設計
論文名稱(外文):The optimal design of micro End-mill for milling SKD61 tool steel
指導教授:李炳寅李炳寅引用關係
指導教授(外文):Bean-Yin Lee
學位類別:碩士
校院名稱:國立虎尾科技大學
系所名稱:創意工程與精密科技研究所
學門:藝術學門
學類:視覺藝術學類
論文種類:學術論文
論文出版年:2009
畢業學年度:97
語文別:中文
論文頁數:77
中文關鍵詞:微小銑削有限元素分析灰關聯分析
外文關鍵詞:micro end-millfinite element analysisgrey relation analysis
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本研究是應用DEFORM軟體,建立一套微小銑削SKD61模具鋼製程分析模型,藉此模型可以瞭解切屑形成的過程,並預測其刀具性能。文中並以直交表規劃微小銑削模擬實驗。製程參數包括有效rake angle、離隙角、切削速度和每刃進給等四個參數。評估微小銑削製程性能主要有切削力、刀具最高溫度、刀具最高溫度與刀尖距離和刀具與切屑接觸長度等四個品質特性,此為多重品質特性問題。應用灰關聯分析將多重品質特性轉換為單一性能指標,即灰關聯度。再以田口參數設計找出滿足多重品質特性製程參數最佳解。
利用刀具研磨軟體搭配五軸工具磨床研磨實驗所需的微小銑刀,對SKD61模具鋼進行微小銑削。最後驗證本研究所建立的準確性,結果顯示有限元素分析結果與實際切削實驗結果的趨勢相同。
In this study, the simulation analysis model for micro milling SKD61 mold steel has been developed by the finite element package software DEFORM. The process of chip formation can be understood by simulating. Orthogonal Arrays is used to experiments scheme of micro milling simulation. The influence of various parameters such as rake angles, relief angles, cutting speeds and feed per tooth have been investigated. The cutting force, tool maximum temperature, tool maximum temperature and tip distance, the contact length of tool and chip are the major performance indexes of micro milling process. This is the issue of multiple quality characteristics. Multiple quality characteristics into a single performance index by applying grey relation analysis, this is grey relation grade. The optimal processing parameters are evaluated by Taguchi parameter design method.
The micro end-mill has been ground by tool grinding software on a 5-axis CNC tool grinder machine. Micro milling for SKD61 mold steel has been performed. In the finished analysis model, the results from the actual cutting experiment are used to confirm accuracy from the finite elements analysis and from the actual cutting experiment are the same.
摘要...........................................................................i
Abstract....................................................................ii
誌謝..........................................................................iii
目錄..........................................................................iv
表目錄.......................................................................vi
圖目錄......................................................................vii
第一章緒論.................................................................1
1.1前言......................................................................1
1.2研究動機及目的......................................................3
1.3文獻回顧................................................................4
1.3.1微小銑削.............................................................4
1.3.2有限元素分析.......................................................5
1.4論文架構................................................................7
第二章理論與方法........................................................8
2.1刀具幾何理論..........................................................8
2.1.1端銑刀具幾何.......................................................8
2.1.2平面銑削..............................................................9
2.1.3三維切削理論......................................................12
2.2田口法..................................................................18
2.2.1實驗計畫............................................................18
2.2.2直交表...............................................................18
2.2.3參數設計............................................................20
2.2.4變異數分析.........................................................22
2.3灰關聯分析............................................................25
2.4有限元素分析.........................................................27
2.4.1DEFORM軟體簡介...............................................27
2.4.2迭代法..................................................... ..........29
2.4.3摩擦條件..................................................... .......31
2.4.4塑流應力.............................................................32
2.4.5材料的塑性法則與性質..........................................32
2.4.5.1塑性流動法則................................................ ...32
2.4.5.2應變硬化、等效應力及等效應變..........................34
第三章實驗規劃與設備.................................................38
3.1研究流程................................................................38
3.2實驗設備................................................................40
3.2.1匠澤B8型高速綜合加工機......................................40
3.2.2TG-5 PLUS工具磨床............................................41
3.2.3M-40工具磨床......................................................42
3.2.4TP-300AE砂輪量測儀..................................... .....43
3.2.5Zoller genius 3刀具量測儀.....................................44
3.2.63D工具顯微鏡量測儀............................................45
3.2.7Haimer TD-99刀具動平衡機...................................46
3.2.8高週波熱感應燒結機.............................................47
第四章微小端銑刀設計模式建構....................................48
4.1微小切削模式建構...................................................49
4.1.1模型建構.............................................................49
4.1.2微小切削分析結果與驗證實驗................................52
4.2微小切削性能模擬分析.............................................53
4.3微小銑削最佳化設計模式建構...................................57
4.3.1實驗規劃.............................................................57
4.3.2模型建構.............................................................58
4.3.3模擬結果.............................................................59
4.4模擬數據分析與討論................................................61
4.4.1灰關聯分析..........................................................61
4.4.2變異數分析..........................................................63
4.4.3最佳水準組合.......................................................64
第五章驗證實驗...........................................................65
5.1有效rake angle實驗分析...........................................66
5.2微小端銑刀研磨.......................................................70
5.3最佳微小銑刀驗證實驗.............................................71
第六章結論與未來展望.................................................72
6.1結論...................................................................... 72
6.2未來展望................................................................73
參考文獻.....................................................................74
簡歷...........................................................................77
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