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研究生:林宗謙
研究生(外文):Tsung-Chien Lin
論文名稱:以油加工液之微線割放電加工電源研發與多晶鑽石加工特性研究
論文名稱(外文):Development of a Pulse Generator for Oil-based Micro Wire-EDM and a Study on Machining Characteristics of Polycrystalline Diamond
指導教授:顏木田
指導教授(外文):Mu-Tian Yan
口試委員:陳順同羅勝益
口試日期:2013-11-21
學位類別:碩士
校院名稱:華梵大學
系所名稱:機電工程學系
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:2013
畢業學年度:102
語文別:中文
論文頁數:86
中文關鍵詞:微線切割放電加工多晶鑽石放電電源
外文關鍵詞:Micro Wire-EDMPolycrystalline DiamondPulse Generator
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本文目的是研發微線切割放電加工機之油加工專用電源系統以降低多晶鑽石加工損傷層並維持穩定加工,為了提供高開路電壓與低放電電流波形,提出兩段式電阻直流電源架構,實驗探討使用油加工液微線切割放電加工之一般多晶鑽石與含硼多晶鑽石的加工特性,實驗結果顯示兩段式電阻直流電源,利用第一段低限流電阻,有效的縮短高開路電壓持續時間讓放電間隙絕緣崩潰產生放電,應用第二段高限流電阻促使放電時的能量能降低,與直流電源比較可獲得較小加工損傷層、較好表面品質與較小表面粗糙度。含硼多晶鑽石比一般多晶鑽石電阻率較低,導電性較好,再加上熱傳導率較小,材料移除較容易,加工切邊比較平整,損傷層較小,加工表面微破裂較少,獲得較佳的表面粗糙度。本文所研發之油加工電源系統可使用ψ50 μm鎢線對一般多晶鑽石進行加工可維持穩定加工且不斷線,最大床台進給速率可達到0.2 mm/min、表面粗糙度為Ra 0.6 μm且熱影響損傷層為7 μm,而含硼多晶鑽石表面粗糙度可達到Ra 0.45 μm,最後實驗結果證實本文所研發之油加工工專用放電電源可實際應用於微線切割放電加工機。
This paper aims to develop a specific power supply for oil-based micro wire electrical discharge machining (wire-EDM). A two –stage current-limiting resistance power supply was presented to suppress thermal damage on the machined surface of polycrystalline diamond (PCD) while achieving stable machining by supplying high open voltage and low discharge current pulse waveforms.
Tests revealed that the two-stage resistance power supply could achieve lower thermal damaged layer, better surface quality and surface finish than a conventional DC power supply. Experimental results demonstrate that boron-doped polycrystalline composite diamond(BD-PCD) is superior to polycrystalline diamond in the smoothness of cutting edge, surface quality and surface roughness since the former has lower specific resistance and thermal conductivity than the latter. This study has indicated that the proposed power supply could enable a prototype micro wire-EDM machine to achieve a surface finish as low as 0.45 μm Ra and a thermal damaged layer as small as 6μm on the machined surface of BD-PCD through proper machining settings.
摘要 ............................................................................................................ II
目錄 .......................................................................................................... IV
圖目錄 ...................................................................................................... IX
表錄 ........................................................................................................ XIII
第一章 緒論............................................................................................... 1
1.1 引言 ........................................................................................... 1
1.2 文獻回顧 ................................................................................... 3
1.1................................................................................................ 3
1.2.1 微放電加工電源相關研究 ............................................. 3
1.2.2 多晶鑽石放電加工相關研究 ......................................... 4
1.2.3 使用油加工液放電加工相關研究 ................................. 6
1.3 動機與目的 ............................................................................... 8
1.4 本文結構 ................................................................................. 10
第二章 放電加工技術 ............................................................................ 11
2.1 放電加工原理 ......................................................................... 11
2.1.............................................................................................. 11
2.1.1 放電現象說明 ............................................................... 11
2.1.2 材料去除機制 ............................................................... 12
2.1.3 放電的基本轉換過程 ................................................... 14
2.1.4 放電火花之結構 ........................................................... 16
2.2 放電電源系統 ......................................................................... 19
2.2.1 依放電迴路分類 ........................................................... 19
2.2.2 依放電能量分類 ........................................................... 22
2.2.3 線切割放電加工機之電源系統 ................................... 24
2.3 線切割放電加工特性 ............................................................. 25
2.3.1 加工速度 ....................................................................... 25
2.3.2 加工精度 ....................................................................... 26
2.4 加工參數變化的影響 ............................................................. 29
第三章 放電電源系統設計 .................................................................... 33
3.1 放電迴路設計 ......................................................................... 33
3.2 放電電源架構與脈波控制方法 ............................................. 34
3.3 電晶體驅動電路 ..................................................................... 40
3.4 多晶鑽石線切割放電加工機制 ............................................. 41
第四章 實驗設備與實驗規劃 ................................................................ 44
4.1 實驗設備 ................................................................................. 44
4.1.1 伺服系統 ....................................................................... 46
4.1.2 繞線機構 ....................................................................... 47
4.1.3 控制器 ........................................................................... 47
4.1.4 線電極 ........................................................................... 48
4.1.5 加工液 ........................................................................... 48
4.1.6 電源供應器 ................................................................... 48
4.1.7 工件材料 ....................................................................... 49
4.1.8 PCD專用電源 .............................................................. 50
4.2 量測設備 ................................................................................. 53
4.2.1 數位示波器(Oscilloscope) ........................................... 53
4.2.2 電流量測系統( Current Probe System ) ....................... 54
4.2.3 電壓差動探棒 ............................................................... 55
4.2.4 光學工具機顯微鏡 ....................................................... 56
4.2.5 雷射共軛焦顯微鏡 ....................................................... 57
4.3 實驗規劃 ................................................................................. 59
第五章 實驗結果與分析 ........................................................................ 62
5.1 兩段式電阻電源與直流電源電壓波形比較 ......................... 62
5.2 放電間隙電壓與電流波形比較 ............................................. 63
5.3 加工溝槽寬與熱影響層比較 ................................................. 66
5.4 加工切邊比較 ......................................................................... 70
5.5 加工表面比較 ......................................................................... 73
5.6 加工表面粗糙度Ra比較 ........................................................ 77
5.7 兩段式電阻電源與直流電源加工性能比較 ......................... 78
第六章 結果與建議 ................................................................................ 81
參考文獻 ................................................................................................... 83
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