臺灣博碩士論文加值系統

本研究探討的為一種新型的硬化性材料加工方法：斜向超音波振動輔助車削。斜向超音波振動輔助是以超音波輔助切削為基礎所發展之技術，利用一特殊結構與壓電致動器之配合，在切削時產生一YZ方向之斜向超音波往復運動(車削加工)。其與橢圓超音波振動輔助車削相比振動軌跡一樣會使得前後刀具面與切屑分離、擁有雙軸向振動之優勢，而且只使用一個壓電致動器因此使結構相對簡單，而簡單的結構與單壓電致動器也能大幅降低刀具的製作成本。
本研究會先針對超音波振動輔助車削加工進行理論探討，並利用振動理論與結構分析軟體模擬，設計一斜向超音波振動輔助車削之刀把，再以刀把進行車削實驗互相比對分析其結果。
實驗利用臥式車床進行車削實驗，刀把頻率為15.9kHz、工件半徑R=11mm、工件長度為L=200mm、振動頻率為f=15.9 kHz、斜向振動振幅為4µm、切削深度 b=10µm，然後規劃兩種切削參數分別為進給速度固定F=32mm/min與固定進給量 S=0.025mm/rev。並以振動速度與切削速度之比值為依據分成三種轉速與有無施加振動來進行六種條件的車削實驗。實驗結果顯示，由於施加斜向超音波振動，擁有兩軸的振動往復式高頻切削，能使得工件之表面品質有所提升、縮短切屑與使切屑能較易脫離工件的效果；而切削之速度比也會影響斜向振動對切削得影響大小，切削比愈大，也就是振動速度大於切削速度時，會有更好的斜向振動超音波輔助切削效果。
本研究欲以此相對簡單的特殊結構、單振動源和較低的成本來達到與橢圓雙軸向振動輔助車削相同之加工效果。如此一來，在工業上就能以更低的成本來加工一些無振動車削所無法加工的材料或是能讓原本加工的材料能夠有夠好的精度與表面品質表現。

This study explores a new type of hardening material cutting method “Ultrasonic oblique vibration assisted turning”.Ultrasonic oblique vibration assistance is based on the development of ultrasonic-assisted cutting technology, use a special structure and the combination of piezoelectric actuators, in the cutting produce a YZ direction of the oblique ultrasound reciprocating motion (turning). Compared with the elliptical ultrasonic vibration assisted steering, the vibration trajectory will make the front and rear tool face separate from the chip, have the advantage of elliptical vibration, and only use a piezoelectric actuator so that the structure is relatively simple, and simple structure and Single piezoelectric actuators can also significantly reduce the cost of tooling.
In this paper, we first discuss the ultrasonic turning assisted machining, and use the vibration theory and structural analysis software to simulate the design of an oblique ultrasonic vibration assisted turning tool, and then compare the results of the turning experiment with the tool.
The vibration frequency is f = 15.9 kHz, the amplitude of the oblique vibration is 4μm, the cutting depth is b = 10μm, and then the cutting frequency is 15.9kHz, the workpiece radius is R = 11mm, the workpiece length is L = 200mm, the vibration frequency is f = The two cutting parameters are fixed for the feed rate fixed F = 32mm / min and the fixed feed rate S = 0.025mm / rev. And the vibration speed and cutting speed ratio is divided into three kinds of speed and with or without vibration to carry out six conditions of the turning experiment. Experimental results show that, due to the application of oblique ultrasonic vibration, with two-axis vibration reciprocating high-frequency cutting, can make the surface quality of the workpiece has improved, shorten the chip and the chip can be easily removed from the workpiece effect; Than the impact of oblique vibration on the cutting effect, the greater the cutting ratio, that is, vibration speed is greater than the cutting speed, there will be better oblique vibration ultrasonic assisted cutting effect.
This study aims to achieve the same processing effect as elliptical ultrasonic vibration assisted turning with a relatively simple special structure, a single vibration source and a lower cost. In this way, in the industry will be able to lower the cost of processing some non-vibration turning materials can not be processed or can make the original processing of materials can have good accuracy and surface quality performance.

致謝
摘要 i
Abstract ii
目錄 iv
圖目錄 vii
表目錄 xiii
符號表 xiv
第1章 緒論 1
1.1 研究動機與目的 1
1.2 文獻回顧 2
1.2.1 超音波輔助切削理論 2
1.2.2 超音波輔助切削刀把與應用 8
1.3 振動輔助車削之分類 34
1.4 研究方法與步驟 36
1.5 論文架構 37
第2章 超音波振動輔助車削加工 38
2.1 切削原理 38
2.1.1 車削加工 38
2.2 超音波振動輔助之驅動原理 39
2.2.1 壓電材料之特性 39
2.2.2 蘭杰文(Langevin) 40
2.2.3 電伸縮振動子 41
2.3 超音波振動輔助加工之特點 42
2.4 超音波振動輔助車削路徑 43
2.4.1 無振動輔助車削路徑 44
2.4.2 一維超音波振動輔助車削路徑 47
2.4.3 橢圓超音波振動輔助車削路徑 50
2.4.4 斜向超音波振動輔助車削路徑 53
2.5 超音波輔助車削表面探討 56
第3章 斜向超音波振動輔助車削刀把之設計 59
3.1 設計構想 59
3.1.1 振動裝置優缺點比較 60
3.1.2 材料選用 61
3.1.3 壓電材料選用 62
3.1.4 裝置作動原理 64
3.2 ANSYS模擬分析 64
3.2.1 ANSYS邊界條件設定與網格調整 64
3.2.2 ANSYS共振模態模擬分析 66
3.2.3 ANSYS動態結構模擬分析 68
3.2.4 ANSYS靜態結構模擬分析 71
3.2.5 ANSYS剛性模擬分析 72
3.3 斜向超音波振動輔助車削刀把性能測試 73
3.3.1 實驗規劃 73
3.3.2 實驗設備與配置 74
3.3.3 阻抗分析 78
3.3.4 量測結果與討論 80
第4章 加工實驗測試與分析 83
4.1 實驗規劃 83
4.2 實驗設備與配置 84
4.3 實驗結果與分析 87
4.3.1 斜向超音波振動輔助加工表面形貌 87
4.3.2 表面粗糙度分析 93
4.3.3 加工切屑分析 95
第5章 結論與未來展望 97
5.1 結論 97
5.2 未來展望 98
參考文獻 99

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