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研究生:廖韋勛
論文名稱:複合材料CNC切削毛邊改善
論文名稱(外文):A Study on the Enhancement of Burr of Composite during Machining Process
指導教授:戴國政戴國政引用關係
口試委員:戴文龍劉勝彰
口試日期:2014-07-14
學位類別:碩士
校院名稱:逢甲大學
系所名稱:機械與電腦輔助工程學系
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:2014
畢業學年度:102
語文別:中文
論文頁數:63
中文關鍵詞:田口方法複合材料CNC加工
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本研究主要在改善與分析,複合材料使用三軸CNC進行特徵孔加工後,會在加工斷面產生的毛邊。斷面毛邊會影響加工孔精度,並需以後製程移除毛邊進而增加生產成本。
實驗中以田口方法討論不同切削參數設定(EX.銑削方向、主軸轉速、切削進給、刀具前角、可繞性支撐材硬度、可繞性支撐材厚度),對毛邊品質的影響性。
以田口實驗之L18直交表進行實驗與變異數分析(ANOVA)結果,最佳參數為逆銑(Factor A)、主軸轉速9000rpm(Factor B)、切削進給100 mm/min(Factor C)、刀具前角14度(Factor D)、可繞性支撐材料硬度Shore A 95(Factor E)、可繞性支撐材料厚度0.3mm(Factor F),且Factor A、B、D、E為對切削斷面毛邊改善之重要因子,可利用其參數進行切削斷面品質改善,而Factor C、F對切削品質影響不大,可應用於製程成品降低。
將最佳製程參數導入,可將毛邊尺寸由平均值0.7mm降低為0.07mm,以有效改善目前特徵孔切削後尺寸及品質等問題。
The purpose of this study is improve the burr issue during composite CNC machining process. The burr issue will impact feature dimension that machining by CNC process and it need to be remove by after process, this requirement will increase the production cost.
Use the Taguchi method to discuss effect of machining quality in difference parameters(EX. cut direction, spindle speed, feed rate, rake angle of tool, hardness of flexible supporter, thickness of flexible supporter)
According to the result of Taguchi&;#39;s L18 orthogonal array, analysis of variation (ANOVA).The optimal machining parameters were combination of up milling(Factor A), spindle speed 9000rpm(Factor B), feed rate 100mm/min(Factor C), rake angle of tool 14°(Factor D), hardness of supporter Shore A 95(Factor E), thickness of supporter 0.3mm(Factor F). And the factor A, B, D, E are important control factor for machining quality. The Factor C, F only slightly effect for machining quality and can be apply to reduce production cost.
After optimal parameter implement, the average of burr dimension could be reduce from 0.7mm to 0.07mm and it will improve CNC machining quality and dimension issue.
目錄
中文摘要........................................................................................ⅰ
Abstract.........................................................................................ⅱ
誌謝...............................................................................................ⅲ
目錄...............................................................................................ⅳ
圖目錄............................................................................................ⅷ
表目錄............................................................................................ⅺ
第一章 緒論.....................................................................................1
1.1.研究動機與目的 ................................................................1
1.2.文獻回顧............................................................................4
1.3.研究範疇與論文架構..........................................................7
第二章 相關理論介紹....................................................................8
2.1.複合材料簡介.....................................................................8
2.1.1.複合材料的定義........................................................8
2.1.2.複合材料的分類........................................................8
2.1.3.強化纖維的種類........................................................9
2.1.4.纖維的型式及規格..................................................10
2.1.5.熱塑型複材樹脂含浸技術.......................................12


2.2. CNC相關原理介紹........................................................14
2.2.1.切削原理..............................................................14
2.2.2.正交切削與斜交切削............................................14
2.2.3.順銑與逆銑..........................................................15
2.2.4.切削進給..............................................................16
2.3.切削刀具........................................................................17
2.3.1.刀具材質.............................................................17
2.3.2.銑刀各部位名稱..................................................18
2.4.田口方法........................................................................19
2.4.1.田口方法步驟.....................................................19
2.4.2.因子種類............................................................21
2.4.3.直交表................................................................22
2.4.4.品質損失函數.....................................................22
2.4.5.信號雜訊比 (signal-to-noise ratio).....................23
2.4.6.變異數分析(Analysis of Variance, ANOVA).......26
2.4.7.確認實驗............................................................28
2.4.8.信賴區間(Confidence Intervals, CI)...................29
第三章 實驗設備及實驗方法.......................................................31
3.1.實驗設備........................................................................31
3.1.1.Brother TC-S2A 三軸加工機............................31
3.1.2. 3D FAMILY_VMP250.....................................31
3.1.3.TPU film..........................................................32
3.2實驗方法.......................................................................32
3.2.1.實驗系統.........................................................33
3.2.2.實驗試片.........................................................34
3.2.3.切削刀具.........................................................35
3.2.4.毛邊尺寸量測..................................................35
3.2.5.測試治具.........................................................36
3.2.6.切削路徑.........................................................37
3.3實驗步驟......................................................................38
第四章 結果討論與分析...............................................................39
4.1. 實驗流程......................................................................39
4.2. 直交表配置..................................................................40
4.3.S/N ratio計算..............................................................41
4.4. ANOVA 變異數分析...................................................44
4.5.預測最佳值與驗證實驗.................................................47
4.6.考慮生產成本之驗證實驗.............................................50
4.7.控制因子對毛邊尺寸之影響.........................................54
4.8.最佳參數導入實務曲面切削前、後狀況.......................57
第五章 結論與建議......................................................................58
參考文獻........................................................................................60
附錄...............................................................................................62
1.劉顯光,郭文雄,許明發,柯澤豪,&;quot;複合材料入門&;quot;,中華民國尖端材料科技協會,2005
2.H.Hocheng and C. K. H Dharan, &;quot;Delamination During Drill in Composite Laminates&;quot;, Transactions of the ASME, Journal of Engineering for Industry, Vol.112, pp.236-239, 1990
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4.António T. Marques a, Luis M. Durão b,*, António G. Magalhães b, João Francisco Silva b, João Manuel R.S. Tavares a, &;quot;Delamination analysis of carbon fibre reinforced laminates: Evaluation of a special step drill&;quot;, Composites Science and Technology 69 (2009) 2376–2382
5.C.C. Tsao a,, H. Hocheng b, &;quot;Taguchi analysis of delamination associated with various drill bits in drilling of composite material&;quot;, International Journal of Machine Tools &; Manufacture 44 (2004) 1085–1090
6.Vijayan Krishnaraj a, *, A. Prabukarthi a, Arun Ramanathan a, N. Elanghovan a, M. Senthil Kumar a,Redouane Zitoune b, J.P. Davim c, &;quot;Optimization of machining parameters at high speed drilling of carbon fiber reinforced plastic (CFRP) laminates&;quot;, Composites: Part B 43 (2012) 1791–1799
7.Wolfgang Hintze *, Dirk Hartmann, Christoph Schutte, &;quot;Occurrence and propagation of delamination during the machining of carbon fibre reinforced plastics (CFRPs) – An experimental study&;quot;, Composites Science and Technology 71 (2011) 1719–1726
8.C.C. Tsao a,*, H. Hocheng b, &;quot;Effects of exit back-up on delamination in drilling composite materials using a saw drill and a core drill&;quot;, International Journal of Machine Tools &; Manufacture 45 (2005) 1261–1270
9.C.C. Tsao a, H. Hocheng (2)b,*, Y.C. Chen b, &;quot;Delamination reduction in drilling composite materials by active backup force&;quot;, CIRP Annals - Manufacturing Technology 61 (2012) 91–94
10.陳彥竹,&;quot;利用抑制機構減少複合材料鑽孔出口脫層&;quot;,清華大學,動力機械工程研究所碩士論文
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