臺灣博碩士論文加值系統

本研究結合切削穩定性分析與實際切削實驗檢視特定刀具在不同切削條件下之工件加工品質。研究中，首先透過振動敲擊實驗擷取機台刀具端頻率響應函數，以及應用切削穩定性分析理論計算刀具端之穩定切削範圍。再依據刀具穩態圖選用切削參數，進行切削實驗，再依據刀具振動及表面品質判斷顫振發生與否，以驗證切削穩定性圖的正確性。其後，使用白光干涉儀量測工件加工表面，取得工件表面形貌及加工面之表面粗糙度。
根據實驗分析結果顯示，切削表面粗糙度與刀具切深及進給率有較高相關性，而主軸轉速之影響程度則明顯小，但整體而言，主軸在6000至7000rpm之間產生較差工件表面精度。另外，非線性預測模型採用二階模型，並考慮切削參數交互關係，相較於其他模型，具有較高準確度，其預測誤差平均值約為16％。在主軸刀具振動分析方面，數據顯示在三不同進給率條件下，任何切深與轉速產生之表粗與刀具振動具有正相關性，其R值均高於0.78，此顯示，刀具振動量越大，所獲得表面粗糙度越差。而非性線回歸分析結果顯示，三種刀具振動預測模型中，以指數型態模型顯示，刀具振動程度與刀具切深、主軸轉速及進給率均呈現正相關性，並具有較高準確度，其預測誤差平均值約為7.39％。其他兩種數學模並無明顯差異，約有26％之預測誤差。此預測模型可應用於估算刀具在不同主軸轉速、切削深度與進給率條件下之振動量及表面精度，其相關性可提供未來切削加工時選用最適當切削參數以減少刀具振動，提升表面精度。

　　High speed and high precision machining has become the most important technology in manufacturing industry. The surface roughness of high precision components is regarded as the important characteristics of the product quality. On the other hand, regenerative chatter occurring in high speed machining could damage the machined surface and restricts the process efficiency and the longevity of cutting tools. To avoid chatter and increase machining precision, most of the engineers have selected the appropriate cutting conditions according the machining stability lobes diagram, but that cannot guarantee the surface quality in good conditions. In order to obtain better surface roughness, the selection of the cutting parameters is a prerequisite. This study was therefore aimed to investigate the influence of the machining conditions on the surface roughness. In study, the stability lobes diagram of a specific cutter was calculated based on the tool end frequency response functions, which was measured by the vibration test conducted on the milling machine. Basically, the stability lobes implied the cutting parameters (spindle speed and cutting depth) for stable machining. Next, a series of machining experiments were conducted. The surface roughness of workpieces was examined by means of the white light interferometer.
　　According to the machining tests, machined surface with or without chattering were marked on the lobes diagram for verification of the machining conditions. On the other respect, the ANOVA analysis reveals that the surface roughness show a positive correlation with machining conditions. Using multivariable regression analysis, the mathematical model describing the relationship between surface roughness (Ra) and cutting depth (a), feed rate (f) and spindle speed (s). The predicted roughness is shown to agree well with the measured roughness, an average percentage of errors of 17%. The average percentage of errors of the tool vibrations between the measurement and the predictions of exponential model is about 7.39%. Also, the tool vibration under various machining conditions are found to have a positive influence on the surface roughness (r=0.78). As a summary of this study, the stability lobes diagram was verified experimentally, which can help to identify the machining conditions without chattering in machining. Besides, a mathematical model was successfully developed to predict the surface roughness and vibration level of the tool under different cutting condition.

中文摘要 I
英文摘要 II
目錄 IV
圖目錄 VIII
表目錄 X
符號說明 XI
第一章 序論 1
1.1研究背景 1
1.2文獻回顧 2
1.3研究目的 5
1.4本文架構 5
第二章 基礎理論 6
2.1銑削之切削顫振 6
2.1.1再生性顫振(regenerative chatter) 6
2.1.2結構模態耦合型顫振(mode coupling chatter) 6
2.1.3摩擦型顫振(friction chatter) 7
2.2切削力方程式 8
2.3切削穩定性分析 12
2.4迴歸分析 15
2.4.1迴歸分析的二大應用方向 15
2.4.2分析的基本統計假設 15
2.4.3 多變數迴歸分析(Regression Analysis) 16
第三章 實驗架構 19
3.1 實驗儀器介紹 19
3.2 實驗步驟及方法 21
3.2.1 執行振動敲擊實驗擷取刀具端FRF 22
3.2.2主軸刀具系統之切削穩定性分析 22
3.2.3切削實驗 22
3.2.4 表面粗糙度之量測 23
3.2.5 應用迴歸分析法建立表面粗糙度之預測模型 24
3.3 實驗設備 24
3.3.1 實驗機台力勁 TC510 CNC 銑床 24
3.4 振動敲擊實驗與切削穩定性分析 25
3.4.1 銑刀X與Y軸項動態響應函數 26
3.5 切削穩定性圖 31
3.6 切削實驗 33
3.6 表面粗糙度之量測 34
第四章 結果與討論 35
4.1 切削實驗 35
4.2 切削穩定性圖驗證 48
4.3切削參數與表面粗糙度之分析 52
4.3.1 不同進給率與切削深度、主軸轉速之表面粗糙度 59
4.3.2 不同切削深度與進給率、主軸轉速之表面粗糙度 59
4.3.3 不同主軸轉速與進給率、切削深度之表面粗糙度 59
4.4 表面粗糙度之預測模型 60
4.5 表面粗糙度與刀具振動量之分析 63
4.6 銑刀振動量之預測模型 68
第五章 結論與未來展望 71
5.1 結論 71
5.2 未來展望 73
參考文獻 74
附錄 79
四刃端銑刀 (進給率0.05 mm/flute) 79
四刃端銑刀 (進給率0.075 mm/flute) 96
四刃端銑刀 (進給率0.1 mm/flute) 113

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