臺灣博碩士論文加值系統

工件在切削加工中所產生的扭曲變形會提高自身的折損率與製
造成本，這種扭曲變形的主因為工件因前續製程所產生的殘留應力
在逐次切削過程當中因部分的材料移除導致工件內部的重新變形，
這種現象現在幾乎無可避免，為改善此種問題，本文使用優化切削
路徑的方法降低最大扭曲變形程度。
為了模擬並評估最佳切削順序，首先要建立一切削用模型，並
設好邊界，再透過鄔詩賢教授開發的有限元素軟體(FEAST)對所建
立的模型進行切削路徑模擬，分析過程為藉由分段線性階段求得切
削過程的非線性變形行為，在數種順序排列組合當中藉由變形與應
力分佈情行判斷何種切削順序是最好的。並根據分析結果，給與實
際加工方面一些數據上的參考，以達到降低工件扭曲變形程度，進
一步達到節省成本的作用。

The distortion of workpieces forms during cutting machining can
result high scrap rates and increased manufacturing costs. The cause of
distortion appearing mainly comes from residual stress exists in
workpiece. The residual stress might be produced when workpieces go
through several manufacturing steps like forging、casting and heat
treatment etc. When the part material of workpieces is taken during
cutting machining step by step, the non-equilibrium between the
workpiece and residual stress makes the workpiece distort into another
deformation appearance. This condition is difficult to avoid. This research
provides an optimum procedure design to reduce the maximum distortion
and scrap rate.
At first, this research creates a model for simulating cutting
procedure and estimating the best cutting path arrangement. Then we
build its boundary and use the Finite Element Analysis of structure
(FEAST) which developed by professor Wu to simulate the cutting
procedure of the model. We use the piecewise linear steps to solve the
nonlinear behavior deformation during the cutting processes. We plan
several path arrangements and decide the optimum procedure with the
deformation and Von mises stress distribution in these procedures.
According to the final analysis, we can produce some useful data for the
practical cutting processes about reducing the distortion of the workpiece.
Then the cost will be reduced by this research successfully.

目錄
誌謝 .......................................................................................................... ii
中文摘要 ................................................................................................. iii
Abstract .................................................................................................... iv
目錄 .......................................................................................................... v
圖目錄 .................................................................................................... viii
表目錄 ..................................................................................................... xii
符號說明 ............................................................................................... xvii
第一 章 緒論 ........................................................................................ 1
1.1 前言 ........................................................................................ 1
1.2 文獻回顧 ................................................................................ 2
1.3 研究目的與方法 .................................................................... 7
第二 章 有限元素公式及切削理論 ..................................................... 9
2.1 有限元素公式(Finite Element Formulation) ................................... 9
2.2 切削分析理論 ................................................................................ 13
2.2.1. 切削順序規劃說明 ............................................................... 13
2.2.2. 執行過程 ............................................................................... 13
vi
第三 章 FEAST 前置處理與MACHCUT 軟體說明 ........................ 16
3.1. 有限元素的模型建立 ................................................................... 16
3.2. 建立FEAST 有限元素模型 ......................................................... 17
3.3. 切削路徑規劃 ...................................................................... 19
3.4. 軟體說明 .............................................................................. 20
第四 章 加工實例模擬 ....................................................................... 21
4.1 機械組件加工實例一 ..................................................................... 22
4.1.1 邊界條件 ................................................................................ 24
4.1.2 路徑順序模擬 ......................................................................... 24
4.2 實例二 : 2050-T84 鋁合金航空薄板模型 .................................... 75
4.2.2 切削分析過程與模型建立 ..................................................... 80
4.2.2.1.3 位移量與應力分析 ........................................................... 84
4.3 實例二:鎳合金圓盤模型 .............................................................. 110
4.3.1 文獻內容 ............................................................................... 110
4.3.2 切削分析過程與模型建立 ................................................... 116
4.3.3 初始殘留應力置入 ............................................................... 117
4.3.4 位移量與應力分析 ............................................................... 117
vii
4.3.5 結論 ....................................................................................... 119
第五 章 結論與未來展望 ................................................................. 121
5.1.結論 ............................................................................................... 121
5.2.未來展望 ....................................................................................... 123
參考文獻 .............................................................................................. 124

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