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研究生:曾彥菱
研究生(外文):YAN-LING TSENG
論文名稱:不同電極形狀對加工特性之影響與放電加工參數之決策
論文名稱(外文):Effect of Different Electrode Geometry on Machining Characteristics and Decision-Making of EDM Parameters
指導教授:蔡曜陽蔡曜陽引用關係
指導教授(外文):YAO-YANG TSAI
口試委員:廖運炫許東亞林廷章黃晧庭
口試委員(外文):YUN-SHIUAN LIAUDONG-YEA SHEUTING-JANG LINHAO-TING HUANG
口試日期:2023-07-26
學位類別:碩士
校院名稱:國立臺灣大學
系所名稱:機械工程學系
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:2023
畢業學年度:111
語文別:中文
論文頁數:86
中文關鍵詞:放電加工參數幾何形狀田口方法放電間隙表面粗糙度
外文關鍵詞:electrical discharge machining parametersgeometryTaguchi methoddischarge gapsurface roughness
DOI:10.6342/NTU202303950
相關次數:
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  • 點閱點閱:20
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  • 下載下載:5
  • 收藏至我的研究室書目清單書目收藏:0
在機械製造產業中,模具為工業製造中不可或缺的部分。模具製造除了使用傳統切削方式,還常與放電加工做配合去完成模具製作,因放電加工具有加工複雜細微特徵、高精度加工、加工高硬度材料以及模具修整等優勢。目前業界放電加工應用於模具的技術與、對品質控管的能力相當成熟。但在放電間隙的設置,至今仍必須依賴操作者的加工經驗去設定,缺乏系統化的策略規劃,是目前放電加工的CAD/CAM仍有進步空間的部分。本研究進行不同加工參數條件的探討,不同幾何形狀的放電間隙變化趨勢為何,探討的加工參數為:電流、電壓、脈衝時間、工作因子與幾何尺寸,先利用田口方法規劃實驗與分析,瞭解各參數的改變對放電間隙的走勢,據此發展出多目標的放電加工決策系統。
研究中利用田口方法直交表L27進行,依田口方法的分析瞭解各設計參數的改變會怎麼影響放電間隙變化的趨勢,放電間隙之計算不考慮電極消耗。探討之加工特性為:加工時間、表面粗糙度、放電間隙,發現加工時間不受形狀影響,受加工面積影響;表面粗糙度不受形狀影響,受電氣參數影響。而放電間隙會受不同形狀影響,正方形與長方形的間隙大小幾乎相同,三角形的放電間隙則平均小於正方形與長方形的放電間隙。
最後依變異數分析發現電流、脈衝時間對加工時間、表面粗糙度、放電間隙的貢獻度皆大於75%,表示控制電流及脈衝時間即可大致掌握加工特性,因此放電參數的決策系統以訂定電流、脈衝時間為首要步驟,後續再依需求用電壓、工作因子進行微調以達到要求之品質。
In the mechanical manufacturing industry, molds are an indispensable part of industrial production. In addition to using traditional cutting methods, mold manufacturing often combine with electrical discharge machining (EDM) to achieve complex and intricate features, high-precision processing, machining of high-hardness materials, and mold finishing. Currently, the application of EDM in mold manufacturing has reached a mature level in terms of technology and quality control capabilities. However, the setup of EDM gap still heavily relies on the operator's experience, lacking a systematic strategy, which has room for improvement in the CAD/CAM of EDM. This research explores different processing parameter conditions and the variation trends of EDM gap for different geometric shapes. The processing parameters include current, voltage, pulse-on time, duty factor, and geometric dimensions. The Taguchi method is used to plan and analyze experiments, understanding the effects of various parameters on EDM clearances and developing a multi-objective EDM decision-making system.
The research uses the Taguchi method with an orthogonal table L27 for analysis to understand how changes in each design parameter will affect the variation trend of EDM gap. The investigated machining characteristics are processing time, surface roughness, and EDM gap. It is found that the processing time is not affected by the shape but influenced by the machining area, and the surface roughness is not influenced by the shape but affected by the electrical parameters. However, the EDM gap is influenced by different shapes, with the gap of squares and rectangles being nearly the same, while the gap of triangles is on average smaller by approximately 0.03 mm compared to squares and rectangles.
Finally, the analysis of variance reveals that the current and pulse on time contribute over 75% to the variations in processing time, surface roughness, and EDM gap. This indicates that by controlling the current and pulse-on time, the machining characteristics can be roughly managed. Therefore, the decision-making system for EDM parameters should give priority to setting the current and pulse-on time, and then adjust the voltage and duty factor as needed to achieve the required quality.
口試審定書 i
致謝 ii
摘要 iii
Abstract iv
目錄 vi
圖目錄 ix
表目錄 xi
第1章 緒論 1
1.1前言 1
1.2文獻回顧 2
1.3研究動機與目的 5
1.4論文架構 6
第2章 相關理論介紹 7
2.1放電加工 7
2.1.1放電加工原理介紹 7
2.1.2放電加工材料移除機制 8
2.1.3放電現象轉換過程 9
2.1.4放電迴路種類 11
2.1.5放電加工參數 13
2.1.6放電加工特性 16
2.2田口方法 18
2.2.1基於品質損失函數之品質特性 18
2.2.2 影響品質特性的因子 20
2.2.3 S/N比 21
2.2.4田口直交表 22
2.2.5田口方法執行步驟 22
2.3表面粗糙度理論 22
2.3.1量測術語 23
2.3.2表面粗糙度表示種類 24
第3章 實驗設備與流程規劃 26
3.1實驗規劃 26
3.2實驗流程圖 30
3.3實驗材料與設備 31
3.3.1放電加工機 31
3.3.2 電極材料 32
3.3.3工件材料 33
3.3.4 絕緣加工液 34
3.3.5 雷射共軛焦 35
3.3.6表面粗糙度量測儀 36
第4章 實驗結果與討論 38
4.1 基本加工參數設定 38
4.2 加工特性量測結果 39
4.2.1加工參數與實際工件結果 39
4.2.2 時間紀錄結果 41
4.2.3工件表面粗糙度量測結果 42
4.2.4工件幾何尺寸量測與放電間隙計算結果 44
4.2.5放電間隙計算 46
4.3 各設計參數對加工特性的趨勢走向 48
4.3.1不同形狀於各設計參數對加工時間之影響 48
4.3.2不同形狀於各設計參數對表面粗糙度之影響 53
4.3.3不同形狀於各設計參數對放電間隙之影響 57
4.4正方形、長方形、三角形之加工特性之統整與比較 62
4.4.1 正方形、長方形、三角形對加工時間的影響比較與分析 62
4.4.2 正方形、長方形、三角形對表面粗糙度的影響比較與分析 64
4.4.3 正方形、長方形、三角形對放電間隙的影響比較與分析 66
4.5放電間隙與加工參數的決策 68
4.5.1放電間隙之重要性 68
4.5.2決策方法流程 69
4.5.3決策方法結果 76
4.5.4結果驗證 78
第5章 結論及未來發展 81
5.1結論 81
5.2未來展望 84
參考文獻 85
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