臺灣博碩士論文加值系統

傳統銑削加工之切削厚度，工業上常以一簡單公式來計算。但隨著科技的進步，微銑削加工已是精密加工的趨勢之一，而在微米尺度下，傳統銑削的厚度公式是否適用，是一值得探討的問題。
本文將探討微米等級之兩刃端銑刀的微銑削切削厚度及銑削力問題。首先，基於銑刀運動幾何，推導刀刃的切削路徑及其理論切削厚度公式，並撰寫Matlab程式做切削厚度分析，再與相關學者的研究做比較，得知於每刃進給量與銑刀半徑的比值到達0.3時，傳統厚度公式在順銑時的平均誤差達到15%，因此已不符合微米尺度下之精度要求。有鑑於此，本文進而推導出一適用於微銑削加工的新厚度模式，並針對傳統厚度模式建立一切削厚度誤差圖，以作為傳統公式適用性之參考。此外，本文並進一步探討此一新厚度模式在刀具偏擺上的應用，並與使用傳統厚度通式的結果做比較。
銑削力是判定銑削加工時工件表面、切削溫度、刀具壽命與磨耗的重要指標之ㄧ。在微銑削的情形下，操作者不易觀測銑刀磨耗且不易做銑削力之線上量測，如加工參數不當，更易導致銑刀斷裂。因此本文採用分開犁切與剪切之力學模式(DGCC)，並應用新的切削厚度公式以建立計算兩刃平面端銑刀銑削力之數值解模式和解析解模式，數值解模式用來驗證解析解模式的準確性。解析解模式可應用於判認比切削常數及計算模擬銑削力，以便於進行微銑削加工前預先調整加工參數，避免刀具之損壞。本研究最後以微動力計實際線上量測銑削力，並比較使用新切削厚度模式與傳統切削厚度所得解析解銑削力與實驗量測值之間的差異。

There is a commonly used formula for the thickness of chip of mill cutting, but it is no longer suitable in advanced micro milling.
Based on the motion geometry of two flutes milling cuter, we derive the theorical thickness of chip of milling, and then propose a new chip thickness model, it is proved more accurate by comparing the results got from proposed formula and others’ and the new chip thickness model can be used extensively in frequency domain for establishing the milling force model and runout analysis.
By considering the ploughing effect and using the derived accurate chip thickness, we apply the DGCC force model to establish the milling force model for two flutes micro end milling. This force model can be applied to identify the specific cutting coefficients. The research measure the milling forces in the experiment by dynamometer and compare these results with these got from the new force model using proposed chip thickness and traditional chip thickness. The results of the comparison reveals that the force model using new chip thickness are more reasonable and correct.

目 錄
頁次
中文摘要………………………………………………………………………..I
英文摘要……………………………………………………………………….II
誌謝…………………………………………………………………………………..III
目錄………………………………………………………………………..….IV
圖目錄………………………………………………………………………...VI
表目錄……………………………………………………………………........X
符號說明…………………………………………………………………………….XII
第一章 緒 論
1.1前言………………………………………………….………………1
1.2文獻回顧…………………………………………………………….5
1.3研究方法及目的…………………………………………………….7
1.4論文架構……………………………………………………………12
第二章 微銑刀刀具路徑與切削厚度分析
2.1刀具路徑軌跡……………………………………..…………….…13
2.2端銑刀刃路徑方程式之推導…….….……………….……............14
2.3 Matlab模擬路徑與分析…………………………………………...15
2.4切削路徑和切削厚度之討論與程式分析.......................................16
2.5切削厚度模擬值與相關論文結果之差異.......................................20
2.6新厚度經驗模式與相關論文結果之比較.......................................25

第三章 新厚度模式在偏擺的應用
3.1偏擺理論……………………………………………………..……30
3.2使用傳統厚度通式的偏擺……….........………….........................31
3.3加入新厚度模式的偏擺…………………..………………………34
3.4結論………………………………………………………………..35
第四章 數值解銑削力模式
4.1銑削力模式簡介…………………………………………………..37
4.2數值解銑削力模式………………………………………………..37
4.3新厚度模式的數值解銑削力模擬………………………………..39
4.4比較結果與討論…………………………………………………..45
第五章 解析解銑削力學模式
5.1解析解力學模式之推導…………………………………………..46
5.2比切削常數之判定………………………………………………..54
5.3新厚度模式之解析解銑削力模式………………………………..57
5.4比較結果與討論……………………………………….………….60
第六章 實作與驗證
6.1實驗機台介紹..................................................................................66
6.2銑削力量測與比切削常數的判定..................................................72
第七章 結論與建議
參考文獻………………………………………………………..………….82

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