臺灣博碩士論文加值系統

本研究為建立鋁基碳化矽複合材料(aluminum-metal matrix complex, AMMC)的加工資料庫，以非傳統線切割放電加工( electrical-discharge wire cutting, EDWC)來取代傳統的機械加工法。實驗材料有三批分別含有不同比例的碳化矽(SiC)，而實驗參數則改變加工電流、時間及切割速度等來全面探討對三種鋁基複合材料的切割性質。
實驗結果顯示，縮孔、鑄疵等缺陷對鋁基複合材料機械性質具嚴重與不利的影響外，對線切割放電加工亦會造成放電集中而斷線，最後無法加工。另在線切割放電加工特性方面：(一) AMMC加工後的表面粗糙度隨放電加工參數的放電時間(on time)值增加而變大，有著相當多的空洞與初晶鋁汽化後凹坑；(二)以迴歸模擬預測AMMC的線切割放電加工速度，其影響因素的重要性依序是：不同比例的碳化矽、放電時間、床台進給率及共晶矽量；(三)線切割放電加工時，需調整銅線在不斷線前提下為最大張力、加工液噴嘴壓力及適當加工液的電阻係數等放電加工參數，並使成最佳的組合，方能使鼓形引起的中央切割部尺寸凹陷問題減至最低，以達精密加工的目的。
鋁基碳化矽複合材料經線切割放電加工後，其表面的軟化變質層與雕模放電加工所產生的硬化層不同外，在OM、Hv和SEM觀察其厚度尺寸也有所不同，變質層及鄰接區域的微結構也改變。碳化矽含量隨放電能量增加而減少，使放電表面的硬度較基地組織為低。

The purpose of this study is to build machining data base of aluminum-metal matrix complex (AMMC), in order to replace traditional machining with non-traditional machining of EDWC. Three types of aluminum-metal matrix complexes were used to develop complex materials of the hardness via different contents of SiC percentage.
Results showed that not only defects of materials casting plausibly was disadvantageous to mechanical properties of aluminum-metal matrix complexes but also led to wire-breakage as machining of EDWC. The effects of aluminum-metal matrix complexes on the characteristics of machinability of EDW as below: (1) With increasing on time of cutting conditions, the surface roughness of aluminum-metal matrix complexes increases. The EDW surface of aluminum-metal matrix complexes was rougher than that of as-cast A356.2 due to microstructure of SiC; (2) The factor's order of cutting feedrate for AMMC measured by simulated regression as followed: thickness of the workpiece, on time, feedrate override of the table, SiC contents; (3) In order to acquire the precision of workpieces by setting higher water flow rate, resistivity of dielectric fluid and wire tension prior to wire-breakage.
The thickness and hardness distributions of remelted layer in cross-sectional area of EDW surface differed from that of EDM. The dimension of remelted layer of AMMC in cross-sectional area of EDW surface was not as the same as in terms of measuring instruments such as OM, Hv and SEM. Although there was the thinner distributions of AMMC than that of A356.2 due to microstructure of SiC changed the microstructure of remelted layer and mechanical properties.

目錄
中文摘要 I
ABSTRACT III
目 錄 V
圖 目 錄 VII
表 目 錄 XI
第一章 緒論 1
1-1 金屬基複合材料 1
1-2 線切割放電加工 2
第二章 文獻回顧 5
2-1 Al-Si 基複合材料簡介 5
2-1-1 純鋁及鋁合金 5
2-1-2 Al-Si 合金 7
2-1-3 添加元素對Al-Si 合金之影響 8
2-2 金屬基複合材料之磨耗性質 11
2-3 線切割放電加工 16
2-3-1 放電加工的起源 16
2-3-2 線切割放電加工精度之研究 17
2-3-3 放電加工原理 20
2-3-4 放電加工之材料移除過程 21
2-3-5 放電現象的基本轉換過程 23
2-4放電電源供應系統 24
2-4-1 放電迴路形式 25
2-4-2放電控制形式 28
2-4-3 線切割放電加工的特性 29
第三章 實驗步驟 37
3-1 A390.1-XSiC的準備 37
3-2線切割機切割 38
3-3 表面性質量測 40
3-4 金相實驗 41
3-5實驗程序 42
第四章 結果與討論 44
4-1進給率探討 44
4-2材料去除率 48
4-3 切割間隙 53
4-4 粗慥度 59
4-5變質層 63
第五章 結論 70
文獻參考 71

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