於全域銑削參數中求得最大材料移除率參數

第五章求得銑削限制條件下可實行之加工參數範圍

6.5 最大材料移除率之銑削參數的求得

6.5.3 於全域銑削參數中求得最大材料移除率參數

利用上小節之方法將3.10 式與 6.5 式結合，並取其上限之響應曲面，

即可求得全域銑削參數之具製程變異的平面度模型，如下6.11 式，並可利用 6.11 式找尋最大材料移除率的加工參數。如下表 6-25 所示，即為全域加工參數以及平面度限制中之具製程變異的最大材料移除率的銑削加工參數。

本研究為使製造者更為方便，因此以上述之方法進行不同平面度限制

limit

下的最大材料移除率之預測。下圖6-16 所示，圖中可看出以平均值

進行預測時，δ

limit

為5 mm 後最大材料移除率開始變為定值，而變異模式為 6 mm 之時開始，其原因為於平均值模式中最大材料移除量參數 (S=19500, tx=0.1, d

a

=0.5)所對應的平面度為 4.53 mm，於變異中為 5.67 mm，

因此若平面度限制大於該模式的最大材料移除率參數所對應的平面度，即會產生此現象。另外平均值模式於全域加工參數中的最小平面度為 0.97 mm，而變異模式為 2.01 mm，因此若平面度限制條件低於該模式之最小平面度時，即無法進行最大材料移除率參數預測，意即此實驗系統無法加工。

而下表6-26 與表 6-27，為不同平面度限制下所預測之最大材料移除率的銑削參數。

2 ' 1 0.5

var ( Mp ) _ave ( Mp ) t ( (1 Mp (X'X) Mp ))

      ^

_(6.11)

表6- 25 於全域加工參數下之最大材料移除率參數製程變異模式平均值模式限制條件 δ

_limit

(mm) 3

最大材料移除率參數之預測

結果

S (rpm)

19500

t x

(mm) 0.041 0.065

d a (mm) 0.5 0.5

MRR

max

(mm

³

/min)

9501.8 15127.2

max

(mm) 2.98 2.98

圖6-16 平面度限制與最大材料移除率之關係圖

1 2 3 4 5 6 7

0 0.5 1 1.5 2 2.5 x 10 ⁴

 _limit (mm) MR R ma x (m m 3 /m in )

UCL

CL

表6- 26 以平均值模式求得不同平面度限制的最大移除率之參數平均值模式

limit

(mm)

S (rpm)

x

(mm)

a

(mm)

max

(mm)

MRR

max

(mm

³

/min)

1 19500 0.032 0.1 0.99 1536.3 1.5 19500 0.032 0.5 1.49 7681.8

2 19500 0.043 0.5 1.99 10163.6 2.5 19500 0.054 0.5 2.49 12645.4

3 19500 0.064 0.5 2.97 15127.2 3.5 19500 0.076 0.5 3.48 17774.5

4 19500 0.087 0.5 3.98 20421.8 4.5 19500 0.098 0.5 4.47 23036 5~6.5 19500 0.1 0.5 4.53 23400

表6- 27 以具製程變異模式求得不同平面度限制的最大移除率之參數變異模式

limit

(mm)

S (rpm)

x

(mm)

a

(mm)

max

(mm)

MRR

max

(mm

³

/min) 1~2 ---- --- --- --- ---

2.5 19500 0.1 0.1 2.46 5058.1 3 19500 0.041 0.5 2.98 9501.8 3.5 19500 0.051 0.5 3.49 12149.1 4 19500 0.062 0.5 3.97 14630.9 4.5 19500 0.073 0.5 4.48 17278.1

5 19500 0.084 0.5 4.97 19760 5.5 19500 0.0958 0.5 5.48 22407.2 6~6.5 19500 0.1 0.5 5.67 23400

第七章結論與建議

7.1 結論

本文分析板形工件製程，並以有效率之實驗設計方法，使製造者可執行既符合板件平面度要求又高製造效率的加工，所得結論如下:

1. 本文建立具製程變異之板件平面度模型，提供使用者於製程變異中，

成功求得符合板件平面度要求之最大材料移除率的銑削參數。

2. 如其他製造者欲建構不同刀具與材料進行板件平面度分析，只需依循本研究之方法，即可得到該條件下的具製程變異之平面度模型，並求得最佳參數。

3. 於本製程的分析中，得知影響平面度最大之因子依序為軸向切深、每刃進給以及轉速，其中以軸向切深之影響最大，而本實驗中之最佳參數為轉速最高、每刃切深最小以及軸向切深最小之參數。

4. 有別於田口法配合響應曲面法之文獻，本研究利用直交表之特性將 L

9

之部分實驗融入Box-Behnken 方法之中，以有效的實驗數量建立較精準之響應曲面。

5. 於殘留應力影響深度實驗結果可得知，若期望所加工之成品的殘留應力較小，則可在最後的製程以較小之軸向切深、低每刃進給以及高轉速進行加工即可，而前製程則可先以較大之軸向切深進行加工，以加快製程速度節省時間成本。

6. 本製程的田口法回應圖中可明顯的看出，軸向切深於 0.1 mm 至 0.3 mm 處，對於平面度影響非常大且劇烈，而於0.3 mm 至 0.5 mm 處，則影響不大，由此可推知實驗之軸向切深對於平面度影響具有臨界效果。

7.2 建議

本研究為使板件製程可執行符合平面度要求又高效率之加工。若希望可進行低汙染、降低刀具成本以及低表面粗糙度之製程，則可依下列建議進行研究。

1. 可考慮使用目前較熱門的微量潤滑，進行低汙染的綠色切削，並探討於微量潤滑下銑削參數對板件平面度之影響，以及建立該平面度之模型。

2. 本文可實行之加工參數的區間中並未考慮切削之不穩定以及銑削強迫振動之現象，因此未來建議於可實行銑削參數中考慮銑切之動態限制條件，以避免表面粗糙度上升、刀具壽命下降以及工具機之損壞。

3. 於本次實驗中皆以槽銑進行加工，因此後續建議可以不同徑向切深納入實驗配置之中，觀察不同徑向切深對於平面度之影響。

4. 考慮表面粗糙度於品質特性的限制中，則可進行更多目標響應曲面的最佳參數求得，如此可使加工之成品表面粗糙度更小亦可符合平面度之限制。

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在文檔中平面度限制下最大銑削材料移除率之研究 (頁 102-0)

第五章 求得銑削限制條件下可實行之加工參數範圍

6.5 最大材料移除率之銑削參數的求得

6.5.3 於全域銑削參數中求得最大材料移除率參數

limit

limit

a

2 ' 1 0.5

var ( Mp ) ave ( Mp ) t ( (1 Mp (X'X) Mp ))

      

limit

S (rpm)

t x

d a (mm) 0.5 0.5

max

3

max

1 2 3 4 5 6 7

0 0.5 1 1.5 2 2.5 x 10 4

 limit (mm) MR R ma x (m m 3 /m in )

UCL

CL

limit

x

a

max

max

3

limit

x

a

max

max

3

第七章 結論與建議

7.1 結論

9

7.2 建議

參考文獻

第五章求得銑削限制條件下可實行之加工參數範圍

var ( Mp ) _ave ( Mp ) t ( (1 Mp (X'X) Mp ))

      ^

_limit

³

0 0.5 1 1.5 2 2.5 x 10 ⁴

 _limit (mm) MR R ma x (m m 3 /m in )

³

³

第七章結論與建議