臺灣博碩士論文加值系統

在現今航太產業當中，加工Inconel 718等高鎳基航太零組件時，由於工件材料的高温強度特性使其加工條件變得十分嚴苛，導致刀具的損耗嚴重，進而影響加工品質及效率。籍由熱輔助來降低材料強度並減少切削力是可以有效解決上述的問題。

目前國内外研究的熱輔助熱源以雷射為主軸，但雷射的高成本以及使用於銑削時，會有刀具與光學組合的結構十分複雜等問題而影響其商品化的利基。因此本研究提出一新式電漿熱輔助銑削的複合加工機制，將放電電極與刀具整合在面銑削（ψ50mm，3片式）的刀座上，並籍由高壓電源放電的電漿熱能完成工件軟化的目的。

本研究前期針對電漿的放電現象設計模擬實驗進行觀察，分別由靜態的電漿觀察，改變電極與工件間的間距與改變電漿的瓦數觀察電漿放電的模式、電極消耗以及溫度變化，接著是自行設計的動態模擬刀具，將電極裝入模擬刀具內，設定不同的加工參數來觀察在旋轉中的電漿變化。

本研究中期使用三刃式銑刀進行電漿複合銑削實驗的測試，其中不斷改良電極材質與電漿電源過電方式，以及使用影像設備記錄銑削機制下的電漿放電過程，或是無銑削的空跑單純觀察電漿放電的放電行為，在實驗的過程中，詳細的將結果記錄並且分析，作為最後新刀具設計的參考依據，再將新刀具上機進行測試。

本研究後期使用自行設計之雙刃雙電極進行電漿複合銑削實驗的測試，再切削的實驗結果中顯示出明顯的放電現象，最後在雙刃雙電極的刀具上，完整探討電漿在各種配電方式以及加工位置的不同展現出的各種電漿放電現象。

In the current aerospace industry, when processing high-nickel-based components such as Inconel 718, the processing conditions become very severe due to the high-temperature strength characteristics of the workpiece materials, resulting in serious tool loss, which in turn affects the processing quality and efficiency. Reducing the strength of the material and reducing the cutting force by heat assisting can effectively solve the above problems.
At present, the heat-assisted heat source studied at home and abroad uses the laser as the main axis. However, the high cost of the laser and the use of the combination of the tool and the optical are complicated, which affects the commercialized niche. Therefore, this study proposes a new type of plasma-assisted milling combined machining mechanism, which integrates the discharge electrode and the tool into the face milling (ψ50mm, 3-piece) tool holder, and softens the workpiece by the plasma heat energy discharged by the high-voltage power supply. the goal of.
In the early stage of the study, the simulation experiment of the discharge phenomenon of plasma was observed. The static plasma observation was used to change the distance between the electrode and the workpiece and change the wattage of the plasma to observe the mode of plasma discharge, electrode consumption and temperature change. This is followed by a self-designed dynamic simulation tool that loads the electrodes into the simulated tool and sets different processing parameters to observe the plasma changes during the rotation.
In the middle of the study, a three-blade milling cutter was used to test the plasma compound milling experiment, in which the electrode material and the plasma power supply over-current method were continuously improved, and the image discharge device was used to record the plasma discharge process under the milling mechanism, or the milling process was not performed. Empty running simply observes the discharge behavior of the plasma discharge. In the course of the experiment, the results are recorded and analyzed in detail. As a reference for the final new tool design, the new tool is tested on the machine.
In the later stage of the study, the self-designed double-edged double electrode was used to test the plasma compound milling experiment. The experimental results of the re-cutting showed obvious discharge phenomenon. Finally, on the double-edged and double-electrode tool, the plasma was completely discussed in various power distribution. The various plasma discharge phenomena exhibited by the different ways and processing positions.

摘要
Abstract
誌謝
目錄
表目錄
圖目錄

第一章.文獻回顧
1.1 研究背景
1.2 研究動機與目的
1.3 文獻探討
1.3.1電漿熱輔助加工
1.3.2雷射熱輔助加工
1.3.3難加工材料
1.4 專利搜尋
1.5 研究方法與架構
1.5.2 本文架構

第二章.實驗原理
2.1 電漿原理
2.2 放電電漿原理
2.2.1電漿產生機制
2.2.2電場電漿原理
2.2.3直流電漿與交流電漿
2.3電漿分類
2.4大氣電漿
2.5不同條件下電漿的變化
2.6匹配電路
2.2 切削原理
2.2.1切削原理
2.2.2切削速度、進給、切削深度、切削力、切削溫度
2.2.3 工具壽命
2.3 Inconel 718材料性質
2.3.1 前言
2.3.1.2超耐熱合金

第三章.實驗設備
3.1 設備魚骨圖
3.2 電漿電源供應器
3.3 CNC銑削加工機
3.3.1 機台主軸資訊
3.3.2 機台進給設計
3.3.3 機器之保養以及注意事項
3.3.4 空壓系統
3.4 測溫設備
3.5 攝影設備
3.6 線下量測設備
3.6.1工具顯微鏡
3.7實驗基材
3.7.1 鋁合金
3.7.2 不鏽鋼

第四章. 旋轉電漿設計與實驗
4.1 簡述
4.2 實驗規劃
4.3靜態實驗
4.3.1實驗流程
4.3.1.1 電極間距
4.3.1.2 電極材質
4.3.2機構設計
4.3.3實驗參數
4.3.4 實驗架設
4.3.4.1 電性量測
4.3.5 實驗結果
4.3.5.1 溫度量測
4.3.5.2 電極消耗
4.3.5.2.1 電極消耗上線上量測
4.3.5.2.2 線下量測方式
4.3.5.3 旋轉電極燒蝕痕跡
4.4 絕緣套環靜態實驗
4.4.1 實驗流程
4.4.1.1 絕緣套環材質
4.4.2 機構設計
4.4.3 實驗參數
4.4.4 實驗架設
4.4.5 實驗結果
4.4.5.1 溫度量測
4.4.5.2 電極消耗
4.4.5.3 旋轉電極燒蝕痕跡
4.5動態實驗
4.5.1 實驗流程
4.5.2 實驗方法
4.5.3 機構設計
4.5.4實驗架設
4.5.5 實驗參數
4.5.6 實驗結果
4.6 總結
4.7 電漿複合銑削切削刀具設計
4.7.1 三刃式銑刀
4.7.2 四刃式銑刀

第五章.電漿複合銑削實驗
5.1 實驗流程與規劃
5.1.1 實驗流程
5.1.2 實驗規劃
5.2 整體實驗及參數設定
5.3 三刃式銑刀刀具電漿熱輔助實驗
5.3.1 DLC類鑽石薄膜鍍層絕緣保護銑刀電漿實驗
5.3.2氧化鋁陶瓷噴塗絕緣保護銑刀使用石墨電極實驗
5.3.3氧化鋁陶瓷噴塗絕緣保護銑刀使用銅箔與刀片作為電極實驗
5.4 雙刃雙電極測試
5.4.1刀具設計
5.4.2 實驗流程
5.4.3 實驗配置與參數設定
5.4.4 實驗結果
5.5 雙刃雙電極空跑電漿模式分析實驗
5.5.1 實驗流程
5.5.2 兩刃放電實驗
5.5.3 四刃放電實驗
5.5.4 結論

第六章 結論與未來展望
6.1 實驗結論
6.1.1 DLC類鑽石薄膜鍍層絕緣銑刀測試
6.1.2氧化鋁陶瓷噴塗絕緣銑刀
6.1.3雙刃雙電極刀具測試
6.2 電漿異位放電原因
6.2.1 正常放電
6.2.2 非正常放電
6.3 未來展望
6.3.1 絕緣刀片
6.3.2 低電壓電漿
6.3.3 電漿電源外部控制模式
參考文獻

[1]經濟部工業局IDB經濟部航空產業發展推動小組,2017.
[2]Carl E. Leshock, Jin-Nam Kim, Yung C. Shin.’’ Plasma enhanced machining of Inconel 718: modeling of workpiece temperature with plasma heating and experimental results’’ Journal of Machine Tools and Manufacture Volume 41, Issue 6, May 2001, Pages 877-897.
[3]ChristianBrecherMichaelEmontsChris-JörgRosenJan-PatrickHermani” Laser-assisted Milling of Advanced Materials” Physics Procedia Volume 12, Part A, 2011, Pages 599-606.
[4]H.Attia(2)abS.TavakolibR.VargasaV.Thomsonb”Laser-assisted high-speed finish turning of superalloy Inconel 718 under dry conditions” CIRP Annals Volume 59, Issue 1, 2010, Pages 83-88.
[5]Tatsuya Sugihara12,Toshiyuki Enomoto” High Speed Machining of Inconel 718 Focusing on Tool Surface Topography of CBN Tool” Procedia Manufacturing Volume 1, 2015, Pages 675-682.
[6]山崎耕造,圖解電漿入門:世茂出版社,2007
[7]http://www.isu.edu.tw/upload/81201/43/news/postfile_22984.pdf.
[8]魏孝寬, "射頻大氣電漿束之研究,"國立清華大學論文,2009.
[9]楊超棨, "介電質常壓電漿產生器之開發及其於質譜分析之應用,"國立中山大學論文, 2010.
[10]張家豪，魏鴻文，翁政輝，柳克強李安平，寇崇善吳敏文，曾錦清，蔡文發，鄭國川, "電漿源原理與應用之介紹, "物理雙月刊,vol.28,2006.
[11]Andreas Schutze, James Y. Jeong, Steven E. Babayan, Jaeyoung Park, Gary S. Selwyn, and Robert F. Hicks, "The Atmospheric-Pressure Plasma Jet: A Review and Comparison to Other Plasma Sources,"vol.26,1998.
[12]程德恩, "功率源頻率對大氣電漿束之影響,"國立清華大學,2013.
[13]簡士傑, "大氣電漿束之電漿特性與應用之研究,"國立清華大學,2013.
[14]李孟儒, "RF電漿源的功率匹配研究,"國立東華大學,2002.
[15]http://en.wikipedia.org/wiki/Main_Page
[16]http://fab.cba.mit.edu/classes/MIT/961.04/projects/RegXuProj/MasProject.htm
[17]Michael A. Lieberman , Alan J. Lichtenberg, ” Principles of Plasma Discharges and Materials Processing , 2nd Edition ” Wiley-Interscience,2005.
[18]http://eportfolio.just.edu.tw/c/document_library/get_file?p_l_id=714875&folderId=746790&name=DLFE-6262.pdf
[19]N. Idris, S. N. Madjid, M. Ramli, K. H. Kurniawan, Y. I. Lee, and K. Kagawa, "Monitoring of laser processing using induced current under applied electric field on laser produced-plasma," journal of materials processing technology, vol. 209, pp. 3009-3021, 2009.
[20]洪良德,切削刀具學,全華出版社,2000
[21]卡巴克林恩/邱雲堯/Kalpakjian,Serope,機械製造,文京圖書出版:大揚總經銷1998
[22]鳴瀧則彥/洪榮哲編譯,難削材料之切削加工,全華出版社1989