臺灣博碩士論文加值系統

在此研究中，使用化學蒸鍍鑽石鍍層刀具 (直刃型三角鑽與螺旋型雙角鑽) 在切削速度 (50-180 m/min) 與進給速率 (0.05-0.15 mm/rev) 之下，鑽削編織形式碳纖維強化聚酯。探討鑽石鍍層刀具鑽削碳纖維強化聚酯之切削力 (切削推力與扭矩)、刀具磨耗與孔品質 (材料出口脫層及真圓度偏擺)，並使用變異數分析 (Analysis of Variance) 來檢視可變因子的顯著性。最後利用決策者可用方程式 (Decision maker’s equation) 建立多重目標之分析模型，藉以達成綜合指標之優化，並搭配顯著因子疊加法得到建議之優化參數區間與預期之品質結果。直刃型三角鑽在第一、第二以及第三刀腹上的磨耗型態分別為刀腹磨損 (Abrasion)、刮痕磨耗 (Scoring) 和鍍層碎裂 (Chipping)；螺旋型雙角鑽頭在第一與第二刀刃上的磨耗型態為鍍層碎裂、層間剝離 (Delamination) 以及刀具破損 (Fracture)。由多重目標之分析模型結果可得知，在平均分配各指標之權重下，直刃型三角鑽適合低階切削速 (50 m/min) 配合低階進給 (0.05 mm/rev) 之加工參數。螺旋型雙角鑽則適合低階切削速 (110 m/min) 配合低階進給 (0.05 mm/rev)。由顯著因子疊加法之分析結果可發現，當門檻值設定為實驗結果區間內之25%時，直刃型三角鑽之最佳化參數分布於切削速度 (50-55.46 m/min) 與進給率 (0.052-0.082 mm/rev)。螺旋型雙角鑽在以真圓度為首要考量之最佳化參數範圍為切削速度(110-137.37 m/min) 配合進給率 (0.05-0.069 mm/rev)；以第一刃刀具磨耗為首要考量，則是切削速度 (158-180 m/min) 配合進給率 (0.05-0.062 mm/rev)。

This work examines cutting force, tool wear and hole quality with novel geometric designs, such as double-point and multi-facet drills with diamond coatings. Experiments were conducted with the variable of cutting speeds (50-180 m/min) and feed rates (0.05- 0.15 mm/rev) under dry conditions and use ANOVA to examine the signification of variables. To achieve the multi-objective optimization, we used Decision maker’s equation to build up the multi-objective optimization model. And use superposition process map to require the optimal range of parameters. The double-point drill presented various tool wear patterns, including chipping, delamination and fracture on the cutting lips. The tool wear patterns on the multi-facet drill included progressive abrasion wear, scoring and chipping along the cutting lips on the first, second and the third facets respectively. From the multi-objective optimization results under equal weighting of each objective, it suggested that the best combination for multi-facet drill is under the cutting speed of 50 m/min coupling with the feed rate of 0.05 mm/rev. In contrast, double-point drill was suggested to be used under the cutting speed of 110 m/min coupling with the feed rate of 0.05 mm/rev. When the threshold was set to be 25% of the range form experimental results, the superposition process map shows the preferable parameters of multi-facet drill are in the cutting speed of 50-55.46 m/min and the feed rate of 0.052-0.082 mm/rev. Double-point drill’s preferable parameters for out of roundness are distributed in the cutting speed of 110-137.37 m/min and the feed rate of 0.05-0.069 mm/rev. For first flank wear are distributed in the cutting speed of 158-180 m/min and the feed rate of 0.05-0.062 mm/rev.

摘要 I
Abstract III
誌謝 V
目錄 VI
圖目錄 IX
表目錄 XI
第一章 研究介紹 1
1.1 研究背景與目標 1
第二章 文獻回顧 2
2.1 碳纖維強化聚酯之鑽削 2
2.2 碳纖維鑽削之刀具磨耗 4
2.3 碳纖維鑽削製程之最佳化 5
2.4 變異數分析 7
2.5 反應曲面 8
2.6 信賴區間 8
第三章 實驗工作 9
3.1 實驗材料 9
3.2 切削刀具 10
3.3 實驗設備 10
3.3.1 加工設置及夾治具 10
3.3.2 切削力量測 11
3.3.3 刀具磨耗量測 12
3.3.4 真圓度偏擺量測 12
3.3.5 材料出口脫層量測 13
3.4 實驗設計 14
3.4.1 Phase A: 鑽石鍍層刀具之磨耗型態 15
3.4.2 Phase B: 切削力、刀具磨耗與孔品質之多指標最佳化 16
3.5 統計與檢定 17
3.5.1. 顯著因子疊加法 18
第四章 實驗結果與討論 19
4.1 Phase A: 鑽石鍍層刀具之磨耗型態 19
4.1.1 切削力分析 19
4.1.2 直刃型三角鑽頭之刀具磨耗演化與型態 25
4.1.3 螺旋型雙角鑽頭之刀具磨耗演化與型態 28
4.2 Phase B: 切削力、刀具磨耗與孔品質之多指標最佳化 30
4.2.1 實驗結果 30
4.2.2 多重目標之分析模型 41
4.2.3 顯著因子疊加法 44
4.2.4 有效驗證測試 (Confirmation test) 47
第五章 結論與未來展望 51
5.1 文獻回顧總結 51
5.2 研究結果總結 51
5.2.1. Phase A: 鑽石鍍層刀具之磨耗型態 51
5.2.2. Phase B: 切削力、刀具磨耗與孔品質之多指標最佳化 51
5.3 未來展望 53
參考文獻 54
附錄一 57
附錄二 58

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