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研究生:張嘉倫
研究生(外文):Jia-Lun Jhang
論文名稱:渦卷銑削參數優化之研究
論文名稱(外文):A Study on Milling Parameters Optimization for Scrolls
指導教授:蔡得民
指導教授(外文):Tsay, Der-Min
學位類別:碩士
校院名稱:國立中山大學
系所名稱:機械與機電工程學系研究所
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:62
中文關鍵詞:表面粗糙度銑削加工田口實驗渦卷加工
外文關鍵詞:Surface roughnessMillingScroll machiningTaguchi’s experimental method
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渦卷 (Scroll)常用於空調系統之壓縮機,渦卷式壓縮機由繞動渦卷與固定渦卷所組成,壓縮時,繞動渦卷對固定渦卷以公轉而不自轉的方式運動,使兩者間的壓縮室發生容積變化。在壓縮過程中壓縮室的密合效果,會直接影響渦卷式壓縮機工作效率,因此在渦卷製造上就必須克服其壓縮室形狀複雜與加工精度要求高之困難。業界為了達到穩定品質生產之目的,大多會使用試誤法(Trial-and-Error)測試各種加工參數,找尋適合的參數組合,這會導致製造成本增加與時間的浪費。為滿足產業需求,需快速找出有利之加工參數,符合渦卷規格設計要求。
為克服渦卷加工的技術挑戰,本論文採用田口實驗設計,利用直交表以少量實驗得出結果,快速找出有利之加工路徑、主軸轉速及進給率等加工參數。為驗證加工後渦卷品質,本論文以量測渦卷輪廓精度及表面粗糙度作為渦卷品質評估之依據。經由田口實驗分析,本論文亦探討加工路徑、主軸轉速及進給率對渦卷品質之影響,歸納出渦卷優化加工參數組合,達到改善渦卷品質之目的。本論文以實際加工案例說明,經由田口實驗後,歸納出優化加工參數組合能達到低輪廓誤差或是具有低表面粗糙度兩種。低輪廓誤差之加工參數為:進給率500 mm/min、主軸轉速10,000 rpm,刀具路徑使用B-spline加工路徑;低表面粗糙度加工參數為:進給率500 mm/min、主軸轉速15,000 rpm,刀具路徑則對表面粗糙度的影響不大。
Scrolls are commonly used in compressors of air conditioning systems. Scroll compressor consists of an orbiting scroll and a fixed scroll. When the orbiting scroll is driven by a motor, it is rotated against the fixed scroll so that the volume of the compression chamber between the two scrolls changed. Because the efficiency of scroll compressors will be affected by the closed effect of compression chambers, scroll machining must be conducted to ensure that profiles of orbiting and fixed scrolls meet the accuracy requirements. In order to achieve production of scrolls with quality, Trial-and-Error tests which often increase the time and cost are traditionally used to find improved parameters for machining. To overcome the difficulties mentioned above, this study proposed Taguchi experimental design based on the orthogonal array to find favorite parameters for machining with fewer amount of experiments. To verify the quality of scrolls, accuracy of scroll profiles and surface roughness are checked to meet the design requirements. Then, the analysis of Taguchi experiments is applied to discuss the tool path, spindle speed, and feedrate which influence the quality of scrolls. Thus the combination of machining parameters for scrolls can increase accuracy of profiles or/and reduce surface roughness. The favorite machining parameters for improved accuracy of profiles are: feedrate 500 mm / min, spindle speed 10,000 rpm, and tool path generated by B-splines. The favorite machining parameters for surface roughness are identified by the federate of 500 mm / min and the spindle speed at 15,000 rpm. The tool path has little effect on the surface roughness.
目 錄
誌謝 …..…..…..…………..………………….………..…………………………... i
摘要 …..…..…..…………..………………….………..…………………………... ii
Abstract …………………………......................…………………...….…………… iii
目錄 ….….......……....……..………………....……......…….…..…………..…… iv
圖次 …..….……………….……….…………..……………..………………..……. vi
表次 ………..…………………..……………………………..…………….……. vii
第 一 章 緒論 ………………………..…………...……...…………………… 1
1.1研究動機與目的 ……………………….....………………………………... 1
1.2文獻回顧 ……………………………….....………………………………... 1
1.3研究方法與流程 …………..………………………...……………………... 2
1.4論文架構 …………………………….....…………………………………... 3
第 二 章 實驗原理與實驗設計規劃 …………………………….….....………. 4
2.1田口方法簡介 ……………………….………………...…………….... 4
2.2穩健參數設計 …………………………….………………...…………….... 4
2.3品質損失函數 …………………….………………...…………….... 5
2.4信號雜訊比 …..……………..…………….………………...…………….... 7
2.5變異數分析 …..………………..…………..……………...…………….... 8
2.6實驗因子的選擇 .………...………………….…….…………………….... 10
2.7直交表 …………………...……………….……………..…...………….... 11
第 三 章 渦卷加工簡介與實驗設備介紹 …...……………...………….……. 14
3.1渦卷簡介 ……………………….…….………………………………….... 14
3.2渦卷加工流程 …………………......….....…..………...…………….... 15
3.2.1鋁合金銑削 .………...………….………………...…………….... 16
3.2.2加工路徑規劃 .………...……….………………...…………….... 16
3.2.3順銑與逆銑 .………...…………….……………...…………….... 19
3.3刀具路徑 .………...…………...……......….……………...…………….... 20
3.4主軸轉速 ……...…………….……….....………………..…………….... 21
3.5進給率 .………...………….…......……………………...……………….... 22
3.6表面粗糙度 ………………………….………………...…………….... 23
3.7實驗平台介紹 ………………………….………………...…………….... 25
第 四 章 實驗結果分析與討論 ………………………………….…...………. 29
4.1田口實驗配置 ……………………….………………...……….……….... 29
4.2輪廓誤差S/N 比計算 ………………….……………...……….……….... 30
4.3輪廓誤差ANOVA 變異數分析 ……………………………….……….... 34
4.4輪廓誤差預測最佳值與驗證實驗 ……………….….……….……….... 37
4.5表面粗糙度S/N比計算 ………………………………..……….……….... 38
4.6表面粗糙度ANOVA 變異數分析 ……………….………….……….... 42
4.7表面粗糙度預測最佳值與驗證實驗 ………………….……….……….... 43
第 五 章 結論與未來展望 ……………………......…………….….....………. 45
參考文獻 ……………….…...………………………..……………………….…… 46
附錄 ……………….…...………………………..…………………………….…… 48
參考文獻
[1]Creux, L., 1905, Rotary engine, U. S. Patent No. 801182.
[2]Iwabe, H., and Shimada, T., 1995, “Establishment of High-Accuracy and High-Efficiency Machining Method for Scroll-Shape Workpiece with End Mill: 1st Report, Proposal of High-Accuracy and High-Efficiency Machining Methods Based on Maximum Chip Area and Surface Roughness.” Transactions of the Japan Society of Mechanical Engineers Series C, Vol. 61, No. 583, pp.1184-1191.
[3]Iwabe H., and Fukuyama, H., 2005, “Study on High Accurate Machining of Scroll Wall by Non-Rotating Tool: Analysis of Machining Accuracy based on Tool Deformation using FEM.” 精密工学会秋季大会学術講演会講演論文集,
pp.1051-1052.
[4]Kato, K., Takeuchi, Y., Maeda, Y., and Yamanaka, T., 2004, “High Precision and High Efficiency Machining of Scroll Compressor Components: Bottom Machining of Orbiting and Fixed Scrolls in Low Wear.” Transactions of the Japan Society of Mechanical Engineers Series C, Vol. 70, No. 695, pp.2126-2132.
[5]Kato, K., Takeuchi, Y., Maeda, Y., Yamanaka, T., and Onozuka, H., 2004, “High Precision and High Efficiency Machining of the Scroll Compressor Pieces: High Efficient Bottom Machining in Consideration of Surface Roughness.” Transactions of the Japan Society of Mechanical Engineers Series C, Vol. 70, No. 697,
pp.2730-2736.
[6]Kato, K., Takeuchi, Y., Maeda, Y., Yamanaka, T., and Onozuka, H., 2005, “High Precision and High Efficiency Machining of the Scroll Compressor Pieces: Improvement of Machining Accuracy in Constant Cutting Point Control.” Transactions of the Japan Society of Mechanical Engineers Series C, Vol. 71, No. 701,
pp.304-310.
[7]Yang, J., Arai1, Y., and Gao1, W., 2009, “Rapid Measurement of Involute Profiles for Scroll Compressors.” MEASUREMENT SCIENCE REVIEW, Volume 9, No. 3, pp.67-70.
[8]田口玄一原著,蘇學恭譯,1991,品質工程: 品質從產品與製程的設計開始,中國生產力中心。
[9]Ghani, J.A., Choudhury, I.A., and Hassan, H.H., 2004, “Application of Taguchi method in the optimization of end milling parameters.” Journal of Materials Processing Technology Volume 145, Issue 1, pp.84-92.
[10]Nalbant, M., Gökkaya, H., and Sur, G., 2007, “Application of Taguchi method in the optimization of cutting parameters for surface roughness in turning.”
Materials & Design Volume 28, Issue 4, pp.1379-1385.
[11]李輝煌,2011,田口方法: 品質設計的原理與實務 第四版,高立圖書有限公司。
[12]張季娜等譯,1993,田口式品質工程導論,中華民國品質學會。
[13]蘇朝墩,1997,產品穩健設計: 田口品質工程方法的介紹和應用,中華民國品質學會。
[14]渦卷式壓縮機. (2016, Dec 25). Retrieved from 台灣日立股份有限公司: http://www.taiwan-hitachi.com.tw/products/products-a/products-a-1-3.aspx
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