臺灣博碩士論文加值系統

現今產品設計的造型多為複雜曲面，由於五軸加工之特性與優勢，使得應用五軸加工技術取代三軸加工成為業界的主流。本研究的目的在於嘗試找出利用五軸銑削曲面時之最佳參數。本研究之實驗機台為本實驗室之床台傾斜旋轉型態之五軸加工機，加工的成品模型為凹型半球面，其材料為NAK80模具鋼。實驗程序為使用L9(34)直交表、計算訊雜比、繪製折線圖和反應曲面、最佳化實驗因子和使用ANOVA分析表驗證田口法的正確性與各因子的貢獻度；實驗的因子有切削速度、進給率、刀具路徑規劃和表面接觸點，同時每因子都設定為三個水準。本研究的品質特性為望小特性，亦即取得較小的表面粗糙度值為佳。實驗結果顯示利用12,000rpm的切削速度、600mm/min的進給率、五軸同動的路徑規劃與360個接觸點可以達到較佳的表面粗糙度。ANOVA分析表也驗證了與田口法的實驗結果是一致的，同時也以刀具規劃因子貢獻度最大，有60.5%的影響力，其次為主軸轉速，接下來為進給率，影響程度最不明顯的為刀具接觸點。除此之外，也進行真圓度的分析，其品質特性也是望小特性，運用與研究表面粗糙度相同的流程得到的最佳化結果為五軸同動放射狀加工路徑，主軸轉速為10000rpm，進給率為900mm/min，刀具接觸點為360個接觸點。真圓度的ANOVA分析也得到與田口法相同的結果驗證了實驗的正確性，同時也發現以路徑規畫因子對真圓度的影響最大，有高達25%的影響程度，其次為刀具接觸點，只有8%，接下來則是刀具接觸點有2%的貢獻度，至於進給率對於真圓度的影響就更小了。

Different kinds of complex surfaces of products have become popular in product design in recent years and consequently 5-axis machining techniques become a mainstream in the manufacturing of the die and moulds used in products mentioned above, because of their features and flexibility. This research applies Taguchi method to find out a set of optimal machining parameters in five-axis milling process. The table rotating-tilting type five-axis machine is used to perform the experimental cutting in this study. The geometry of die is modeled as convex half spherical surface, and the material of die is NAK 80 die steel. Experimental procedures consist of using L9(34)orthogonal array, calculating S/N ratio, charting broken-line graph, and response plane, optimizing parameters, an applying ANOVA analysis chart to verify Taguchi experiment results. The four parameters studied are cutting speed, feed rate, tool paths, and contact points, and each of these factors has three levels. The target of this study is the feature of smaller-the-better that is minimization of the surface roughness. The final results of optimal surface roughness experiment shows that the optimal parameters are 12,000rpm cutting speed, 600mm/min feed rate, five-axis tool path, and 360 contact points. The results of ANOVA analysis is correspondent with our research and that can prove Taguchi method is effective. The factors contributing most to the improvement of surface roughness is tool path which accounts for 60.5%,the second is spindle speed. Besides surface roughness, we also conduct research for roundness using the same experiment procedures applied for surface roughness because they have the same quality character. The optimal machining parameters for roundness is 10,000rpm cutting speed, 900mm/min feed rate, five-axis tool path, and 360 contact points. The results of ANOVA analysis is correspondent with our research and that can prove Taguchi method is effective. The factors contributing most to the improvement of surface roughness is tool path which accounts for 25%, the second is tooling contact point.

目 錄

中文摘要 i
英文摘要 ii
誌謝 iv
目錄 v
表目錄 vii
圖目錄 viii
第一章 緒論 1
1.1 研究動機 1
1.2 文獻回顧 2
1.2.1 五軸加工機加工複雜曲面實例 2
1.2.2 NAK80模具鋼應用之研究 4
1.2.3 田口實驗方法應用於工業製程之研究 5
1.2.4 加工參數對於表面粗糙度的影響 9
1.3 研究目的與方法 12
1.3.1 研究目的方法 12
1.3.2 研究流程 13
1.4 本文架構 15
第二章 實驗原理與實驗因子的選擇 16
2.1 田口實驗方法 16
2.2 雜訊:造成品質差異的原因 17
2.3 損失函數與訊雜比 17
2.3.1 望目特性 19
2.3.2 望小特性 19
2.3.3 望大特性 20
2.4 實驗設計 20
2.5 ANOVA變異數分析 21
2.6 表面粗糙度 23
2.7 真圓度 26
2.8 實驗因子的選擇 28
2.8.1 刀具路徑 29
2.8.2 主軸轉速 29
2.8.3 進給率 30
2.8.4 刀具接觸點 31
2.9 田口實驗配置 33
第三章 實驗加工過程 36
3.1 加工機具與刀具 36
3.1.1 五軸工具機簡介 36
3.1.2 實驗用五軸工具機介紹 37
3.1.3 加工刀具介紹 38
3.2 加工材料介紹 40
3.2.1 NAK80模具鋼 40
3.2.2 代木塑膠材料 41
3.3 電腦輔助設計軟體的介紹 41
3.4 模型的建構與後處理 42
3.4.1 模型的建構與選用 42
3.4.2 加工路徑規畫 43
3.4.2.1 平面端銑削 44
3.4.2.2 球面粗銑削 45
3.4.2.3 精加工三軸同心圓狀加工路徑 46
3.4.2.4 四軸同心圓狀加工路徑 46
3.4.2.5 五軸放射狀加工路徑 47
3.5 加工前之準備 49
3.5.1 五軸工具機旋轉中心 49
3.5.2 刀具補正 50
3.5.3 加工座標原點 52
3.6 五軸實際加工過程 54
第四章 實驗結果與分析 57
4.1 加工成品介紹 57
4.1.1 三軸同心圓狀加工路徑之成品 57
4.1.2 四軸同心圓狀加工路徑之成品 58
4.1.3 五軸放射狀加工路徑之成品 58
4.2 成品特徵之量測 59
4.3 田口方法分析 64
4.3.1 表面粗糙度之田口分析 64
4.3.2 真圓度之田口分析 67
4.4 成品特徵之ANOVA變異數分析 70
4.4.1 表面粗糙度之變異數分析 70
4.4.2 真圓度之變異數分析 75
第五章 結論與建議 77
5.1 結論 77
5.2 建議 78
參考文獻 79

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