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研究生:李家欣
論文名稱:最大高速銑削加工參數研究
論文名稱(外文):Study on Parameters for Peak Performance of High Speed Milling
指導教授:溫超東
口試委員:陳育堂 劉履新 溫超東
口試日期:2016-06-28
學位類別:碩士
校院名稱:中華科技大學
系所名稱:機電光工程研究所在職專班
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:2017
畢業學年度:105
語文別:中文
論文頁數:35
中文關鍵詞:高速切削
外文關鍵詞:High Speed Machining (HSM)
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中文摘要
本論文在於研究CNC銑床高速切削,使用4刃、刀徑8 mm超微粒鵭鋼銑刀,刀刃長20 mm,切削工件為S50C中碳鋼。主要目的在於研究此刀具最快的可能切削速度,刀具路徑為MASTERCAM X9之2D高速切削,包括擺線式銑削和動態區域銑削。擺線式銑削的目的在於測試刀具以側邊(Profile)進刀時可使用的最高切速,區域銑削用於高速挖槽加工,在Z方向進刀時將以螺旋路徑切削到設定深度,刀具不再僅側邊切削,而是溝槽(Slot)進刀。區域銑削的目的在於測試高速切削中的Slot切削可達到最高速切削條件。本研究分別在2,000 rpm、5,000 rpm、8,000 rpm的轉速下測試進給率,步進切深(Step Over)為0.8 mm 。擺線式銑削的切深為13 mm 和15 mm,實驗過程中並收集切屑,以顯微鏡觀察以試從切屑了解刀具的磨耗。區域銑削切削範圍為50 mm x 50 mm、深度為10 mm的槽。實驗發現高速切削並沒造成刀具明顯的磨耗,進行高速區域銑削,其關鍵參數為下切時的螺旋切削角度,角度為0.5度時,無需特別考慮因大進給率而造成向下切削時刀具損壞。實驗驗證擺線式銑削和區域銑削在刀刃的長度內進給率都可達到0.25 mm/刃,即在5,000 rpm時,進給率可達5,000 mm/min,在8,000 rpm時,進給率可達8,000 mm/min。

關鍵詞:高速切削、高速銑削、進給率、擺線式銑削、區域銑削、超微粒鎢鋼銑刀

Abstract

This research was focused on exploring high speed milling. A 8 mm diameter 4-flute ultra-fine grain tungsten carbide end mill with 20 mm of length was used for the cutting. The S50C mild carbon steel was selected as the work piece material. The purpose was to exam machining parameters for the peak feed rates. Tool paths used were the 2D high speed peel milling and the 2D high speed dynamic area milling created by MASTERCAM X9. Peel milling was to exam the highest feed rate for the profile cutting. During area milling, both slot and profile cuttings were occurred. Hence area milling was also studied in order to understand the peak parameters can be used for the slot cutting during the spiral path of plunging process.
Feed rates used for this study were 2000 rpm, 5000 rpm, and 8000 rpm. The stepover was 10% of the tool diameter, i.e. 0.8 mm. The cutting depths for peel milling were 13 mm and 15 mm. Chips were collected after cutting and observed under microscope to realize the wearing of the cutter. The milling area was 50 mm x 50 mm x 10 mm deep. It was found that the high-speed milling did not cause the tool more wearing than the conventional milling. For high speed area milling, the key parameter was the plunge angle. Experiments showed that if the angle was larger than 0.5°, chattering or even breaking the tool could happen. In our experiments, the peak feed rate can reach 0.25 mm/tooth with full tool length of cutting depth for both peel milling and area milling. The peak feed rate was 5,000 mm/min at 5000 rpm, and was 8,000 mm/min at 8,000 rpm.
Keywords:High Speed Machining (HSM), High Speed Milling, Feed Rate, Peel Milling, Area Milling, Ultra Fine Grain Tungsten Carbide End Mill

目次

中文摘要…………………………………………………………………………… i
英文摘要…………………………………………………………………………… iii
目次…………………………………………………………………………………… v
表目錄……………………………………………………………………………… vii
圖目錄…………………………………………………………………………… viii
第一章研究方向及動機……………………………………………… 1
第二章研究背景…………………………………………………………… 3
2.1概論………………………………………………………………………… 3
2.2銑削參數…………………………………………………………………… 3
2.3高速切削介紹…………………………………………………………… 4
2.3.1高速切削在世界的發展……………………………………… 4
2.3.2高速切削理論的出現………………………………………… 5
2.3.3高速切削理論……………………………………………………… 5
2.3.4高速切削的優點…………………………………………………… 6
2.3.5高速切削參數……………………………………………………… 7
2.3.6高速切削的電腦輔助軟體………………………………… 7
2.3.7切削觀察…………………………………………………………… 8
2.4刀具壽命…………………………………………………………………… 9
2.4.1刀具形式與發展…………………………………………………… 9
2.4.2刀腹磨耗…………………………………………………………… 9
2.4.3凹坑磨耗………………………………………………………… 9
2.4.4刀鼻磨耗………………………………………………………… 10
2.4.5碎削現象………………………………………………………… 10
2.4.6刀具對於工件表面精準度的影響…………………… 10
2.4.7刀具材料………………………………………………………… 11
2-5切削液…………………………………………………………………… 12
2.5.1切削液的使用目的……………………………………………… 12
2.5.2切削液的作用…………………………………………………… 12
2.5.3切削液的型式…………………………………………………… 12
2.5.4切削液的施加方式……………………………………………… 13
2.5.5切削液的選用…………………………………………………… 13
2.5.6切削液的發展…………………………………………………… 14
2.6銑削方式………………………………………………………………… 14
2.6.1輪廓銑削………………………………………………………… 14
2.6.2面銑削…………………………………………………………… 15
2.6.3端銑削…………………………………………………………… 15
2.6.4鞍銑削…………………………………………………………… 15
2.6.5成型銑削………………………………………………………… 15
2.6.6電腦輔助軟體中的2D高速加工銑削……………… 15
2.7高速切削與傳統切削的差異…………………………………… 16
第三章 研究方法……………………………………………………………… 16
第四章 結果與討論…………………………………………………………… 21
4.1側邊銑削………………………………………………………………… 21
4.2槽穴切削………………………………………………………………… 26
第五章 結論………………………………………………………………………… 28
第六章 未來展望…………………………………………………………………… 29
第七章 參考文獻…………………………………………………………………… 31
第八章 作者簡歷…………………………………………………………………… 34

1.高速切削-互動百科
http://www.baike.com/wiki/%E9%AB%98%E9%80%9F%E5%88%87%E5%89%8A

2.高速切削-維基百科https://zh.m.wikipedia.org/zh-tw/%E9%AB%98%E9%80%9F%E5%88%87%E5%89%8A.

3. “超高速加工,” 台灣word http://www.twword.com/wiki/%E8%B6%85%E9%AB%98%E9%80%9F%E5%8A%A0%E5%B7%A5.

4.台灣WiKi刀具材質:碳化鎢.陶瓷.氮化鋁鈦三種材質http://www.twwiki.com/wiki/%E9%AB%98%E9%80%9F%E5%88%87%E5%89%8A.

5.主軸性能對高速切削加工之影響http://towaagkgj.pixnet.net/blog/post/61431635-%E4%B8%BB%E8%BB%B8%E6%80%A7%E8%83%BD%E5%B0%8D%E9%AB%98%E9%80%9F%E5%88%87%E5%89%8A%E5%8A%A0%E5%B7%A5%E4%B9%8B%E5%BD%B1%E9%9F%BF3.

6.“High-Speed Machining for Aerospace,” March 1, 2008, http://advancedmanufacturing.org/high-speed-machining-aerospace/

7.“High Speed & High Performance Machining-A Tour of High Speed Roughing and Finishing from a CAM perspective,” Cimatron Group.

8.M. Held, C. Spielberger, “A Smooth Spiral Tool Path for High Speed Machining of 2D Pockets,” Computer-Aided Design, 41, 2009, pp. 539-550.

9.B. Zhou, J. Zhao, L. Li, R. Xia, “A Smooth Double Spiral Tool Path Generation and Lining Method for High-Speed Machining of Multiply-Connected Pockets,” Precision Engineering, 46, 2016, pp. 48-64.


10.S. Wu, W. Ma, B. Li, C. Wang, “Trochoidal Machining for the High-Speed Milling of Pockets,” Journal of Materials Processing Technology, 233, 2016, pp.29-43.

11.“Uncover Peak Performance in HSM,” Siemens Product Lifecycle Management Software Inc., 20 July 2010.

12.X. Cui, J. Zhao, X. Tian, “Cutting forces, chip Formation, and tool wear in high-speed face milling of AISI H13 steel with CBN tools”, Int. J. Adv. Manuf. Technol., vol. 64, no. 9-12, pp. 1737- 1749.

13.I. Besliu, L. Slatineanu, M. Coteata, D. Amarandei, “Chip Deformation in High Speed Face Milling of the Hard Tool Steel X210CR12, “ Annals of the Oradea University, Fascicle of Management and Technological Engineering, ISSUE #1, MAY 2014, http://www.imtuoradea.ro/auo.fmte/

14.“CUTTING DATA RECOMMENDATIONS,” Uddeholm Corrax, http://www.uddeholm.com/files/Cutting_Data_Corrax_eng.pdf

15.“GREENFILED INDUSTRIES CLEVELAND,” https://www.gfii.com/images/CTD_Carbide_EM_Specifications.pdf page 17.

16. Rafal Pasko. Lucjan Przybylski and Bogdan Slodki, "HIGH SPEED MACHINING(HSM)-THE EFFECTIVE WAY OF MODERN CUTTING,”page 75.

17.H. Schulz, “The History of High-Speed Machining,” Revista De Ciencia & Tecnologia 13, June 1999, pp. 9-18.

18.T. Kitagawa, A. Kubo, K. Maekawa, “Temperature and Wear of Cutting Tools in High-Speed Machining of Inconel 718 and Ti 6Al 6V 2Sn,” WEAR, Volume 202, Issue 2, January 1997, pp. 142-148.

19.“The Application of High Speed Machining,”Metalworking World, pp. 6-12, https://www.cnc.info.pl/download.htm?id=19004&special=86.

20.B. Zhou, J. Zhao, L. Li, and R. Xia, “A Smooth Double Spiral Tool Path Generation and Lining Method for High-Speed Machining of Multiply-Connected Pockets,” Precision Engineering, 46, 2016, pp. 48-64.


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