高速切削SKD61模具鋼刀具之幾何角度切削性能分析

(1)

㋧Ⳍӡԇ SKD61 ᑁң⻘ӝңʠಂ̬⤑ಙӡԇඖ⋱Ӡኔ

߼ࢁṙ¹ʳ ܨ෢⧷²ʳ ޕ੢ഫ²

1ഏمॡݠઝݾՕᖂ೯Ժᖲඳߓ

2ഏمॡݠઝݾՕᖂᖲඳ፹ທߓ

ၪ ⣬

ᲿԊ᮫ᅠߡもὊᦩ⎞ఱࢍ⃥׶ʠ೼ջ⬹՛ŊҪԽʀߡҙ⃻ᠰ෼՛᱿Ⱨ⩐Ŋ Ⲧ͐׆ሷ᱿Ὂᦩѭ՛ᲩاⲻⱧŊߡҙೇۄ₥₥Ẽദᙹक༼⫏ᮝᮟŊॖ̬ဏᆒᮟ Ꮘ༬⠛ᖛ᜾דᄮ㋤ᮟٴծ⡶Ŋ˫ဏ㋧ὊᦩԻᆯᄎಓ⎞Ꮘ᮹㈪⣬ՁԻᲿᐻʠɺȯ

㋧Ⳍ⺊ԇӝңఱࢍŊ᮫ᅠߡҙ⢌ⳍᏈ໣ᑁңᏈ߱ӝң᱿࿮ᮢʀŊദദ۹฻ⴆႹ ᕗߡҙᮝᮟʠӝң⪽ʀ 3~4 Φ᱿ߡकӝңŊἄҢ׆ߌʜᆯଃ቏߭ᮟٴᗞሷΒൔ ʠᄑŊʈߡҙӝң⢌ⳍۄⵣ଼ᅠ 20 ː˫ʁ᱿ଅࠣ˺ᏈŊᶇᱹ⋱Ի೸Ŋ໽˫ᮟ ٴञⵒ˷༫⣢ߡकȯ

቏ᶇἄરໞɺह೘ᐉરᄮʠ㋧ⳌὉ⺊ӝң᱿ಂ̬ഐᨊאᄲŊଃӡԇ SKD61 ᑁң⻘᱿ӡԇඖ⋱ഛㅨʠӠኔᑁೣŊרဏᆒߡҙӝң⢌ⳍۄ᱿⿭ᱹ⥑⤺⋱ԻŊ Ⳗ≟ೖ̖ᔍᶇἄໞኞᑁೣଃҢ઩ቨᅆ (⺭׶⸉Ȯ⹃׶⸉ƥ) Խడ໽トӝңʠ⥑

⤺⿭ᱹŊ֯ᆯ૽⿭ᱹ⥑⤺༬⠛᱿ Know-How ೘Ἴ߱ߡҙӝң⢌ⳍೇۄُҝ׮

ҙŊ͐ʑଅ˺ᏈऽહࡣḞʏᖝ↲⃻᥸ȯ

〦⼫⥱Ř೏ຒףՠΔ֊চ೶ᑇΔԸࠠ༓۶Ζ

THE ANALYTICAL OF MACHINABILITY OF END-MILL GEOMETRYFOR HIGH SPEED MILLING SKD61 TOOL STEEL

Dai-Jia Juan¹ Huai-Shiun Lu² Bean-Yin Lee²

1Department of Power Mechanical Engineering

National Huwei Universty of Science & Technology Yunlin, Taiwan 632, R.O.C

2Department of Mechanical Manufacture Engineering National Huwei Universty of Science & Technology

Yunlin, Taiwan 632, R.O.C

Key Words: HSM, cutting performances, tool geometry.

ABSTRACT

Because of international competition, the integration of world markets, and the environment of economic conditions, the advantages we had have gone away. That has caused many factories to move overseas for good profits. It becomes more and more important for factories to promote the techniques of production in Taiwan. Although the prices of HSM end-mill tools made in Taiwan is 1/4 to 1/3 of those made by advanced countries, the factories in Taiwan use cutting tools made by advanced countries rather than those made in Taiwan in the high speed machining (HSM) field. This

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shows that engineers in the cutting field have less confidence in the cutting tools made in Taiwan. One of the reasons announced by cutting engineers is that the tool manufacturers in Taiwan are too small to do research and design in the field of HSM cutting tools.

The main purpose of this project is to construct an analytic model which shows the relationships between the geometry of end-mills and the cutting performance of SKD 61 mold-die steel. The (R&D) ability of tool manufacturers in Taiwan shall be improved by using this system. Also, tool manufacturers can model this system for other materials (Aluminum, Titanium,…) in their advanced tool designing. That is to say, the know-how of tool design can be enhanced in the factories which still stay in Taiwan.

Also, the factories shall promote their competitive position in the world.

ɺȮԊ ⤵

ؾছՠࠠᖲհૹ૞᝟Ⴈਢ೏ຒ֏ݾ๬ऱ࿇୶Δۖ೏ຒ

֏ݾ๬ऱ࿇୶ױ։੡ࠟຝ։Δԫ੡೏ຒ֊চݾ๬ (High

Speed Machining

ΔHSM) ׼ԫܛਢ೏ຒၞ࿯ݾ๬Ζ೏ຒ֊

চ֗೏ຒၞ࿯ݾ๬ਢء׈זݾ๬ૹ૞ऱԫᛩΔֲءՠࠠᖲ ᐗ೸੡०൷ء׈ધऱࠐᜯΔ௽ܑಾኙء׈זՠࠠᖲઔᚵՠ

ࠠขᄐآࠐհ࿇୶೯ٻΔࠡխܛല೏ຒ֊চ֗೏ຒၞ࿯ݾ

๬٨Ե࿇୶ऱૹរΔ៶ط׌ၗΕၞ࿯հ೏ຒ֏Δၞԫޡ༼

֒ขᄐऱسขய෷Ζ

ԫ౳Գኙ೏ຒ֊চ່୲࣐ขسհळរ੡Κ 1.೏ຒ֊চ ףՠലࠌԸࠠ߰ຒᗣჾΔᖄીףՠګءᏺ೏ۖլࠠᆖᛎய 墿Ζ 2.೏ຒ֊চףՠႛᔞش࣍᎘ٽ८Δڕᔱٽ८ΕᎭٽ८

࿛ޗறΖ܀ط࣍Ըࠠޗற࿇୶߰ຒΔࠌ൓Ըࠠऱ࿏৫Εર ᗣࢤΕႇࢤ൓אࣔ᧩ޏ࿳ΔࠃኔথᢞࣔԱ೏ຒ֊চΔࠌ൓

ףՠழၴᜍ࿍Աપ 20 %~50 %Δࠀ׊ط࣍ՠٙ।૿٠৫Օ

༏༼֒ፖՠٙᑷ᧢ݮ྇֟ΔՈڂڼ྇֟ᑷ๠෻ழၴא֗ګ ءሒ 80 %Ζຍࠄإٻऱܓ墿ኙ࣍ᅝվՠᇷ೏ይΕՠ܂ழᑇ

ֲ墿ᜍ࿍հषᄎۖߢΔᖞ᧯ףՠګء֘ۖ૾܅Δسขய෷

ঞ଍ᏺΖ೏ຒ֊চ੡ԫጟ೏ຒ֊চຒ৫֗೏ၞ࿯܀܅֊চ

෡৫ऱ֊চֱڤΔլ܀ױא༼೏ޗறฝೈ෷֗૾܅ףՠழ

ၴፖګء؆Δࠀڂ֊চຒ৫೏Δՠٙऱ।૿঴ᔆઌᅝᚌߜΔ

௽ܑᔞٽ౰֜ሿٙፖᑓࠠףՠᄐΔڂڼ೏ຒ֊চݾ๬๯ီ

੡آࠐԼڣᖲඳՠᄐ׌૞ᣂ᝶ݾ๬հԫΔףאഏփᖲඳข ᄐ२ڣࠐឈດޡሀԵᇠᏆ഑ΔՈຬᥛ֧ၞ HSM ऱઌᣂݾ

๬Δ܀֧ၞऱݾ๬ೣૹڇข঴ᐋڻऱسขࢨਢԸࠠऱז

෻Δኙ࣍ઌᣂऱഗ៕ݾ๬լᓵਢ೏ຒ׌ၗऱ๻ૠسขݾ๬

ࢨਢઌኙᚨऱ൳ࠫᕴא֗ CAD/CAM ຌ᧯ݾ๬ऱ࿇୶ፖჸ

಻Δࢨਢ֊চݾ๬ऱ֭ག࿛ຟ੷੡ᜳஇۖڶઌᅝ૰֊ऱᏁ ޣΖۖઌኙ࣍࿏ޗ֊চࢨ೏ຒ֊চհףՠᛩቼΔႨؘ૞ڶ

೏࿏৫Εરᗣ౛Ըࠠፖհ಻ٽΔࡨ౨୶෼נ೏ຒ֏ݾ๬հ ᖞ᧯פயΔ༉ቝ܄ᑗհ࣍Տߺ್Δ໢ڶՏߺ್ۖ޲ڶ܄ᑗ ऱᇩΔലᣄא࿇ཀ،ऱய౨Ζڂڼಾኙᔞش࣍೏ຒᎵচԸ

ࠠऱၲ࿇Δ༉᧩൓ઌᅝऱૹ૞Ζ

ᙟထઝݾऱၞޡΔ२ڣࠐ೏ຒףՠऱݾ๬Δڇ೏ຒף

ՠ ᖲ ፖ ࡌ ᢰ ݾ ๬ լ ឰ ၞ ޡ Հ Ι ດ ዬ ګ ९ ޓ ᝟ ݙ ໂ Ζ

Schulz[1,2]

ڇ२༓ڣ࿇।Ա๺ڍᒧऱઌᣂᓵ֮Δࡳᆠנ೏

ຒ֊চऱటإრᆠΔ׊ᎅࣔ೏ຒ֊চլႛ༼೏سขԺհ

؆Δࠡ֊চԺ૾܅Δՠٙࡉ݈਍ߓอᑷ᧢ݮ྇՛Δ।૿ษ ᜋ৫ߜړΕ֊চழޓ᡹ࡳࢤΖTlusty[3]ኙ೏ຒ֊চऱ᡹ࡳ

ࢤՈ༼נԫ୚෻ᓵΖഏփᖂृᓐݳګ[4]ኙᑓࠠٽ८೚೏ຒ Ꮅচ່ࠋ֊চ೶ᑇՈ೚ԱԫࠄઔߒΖ׼؆ᝫڶԫࠄᖂृ

[5,6,7,8,9,10]

ኙ೏ຒ֊চᚨش࣍լٵޗறऱ֊চࢤ౨೚ԫ

ࠄઔߒΔፖ೏ຒ֊চհ࿇୶೚ԫࠄ։࣫ΖShatla[11]ܓش

FEM

৬مᨵᙰፖ෺ݮᎵԸऱ։࣫ᑓڤΔEngin[12]ಾኙԫ౳

ᝅ ඝ ጤ Ꮅ Ը ৬ ዌ ࠡ ֊ চ Ժ ፖ ೯ ኪ ᑓ ڤ Δ Taylan[13] א

DEFORM

ຌ᧯Δ৬ዌנױቃྒྷ೏ຒؓᎵԸڇ֊চףՠழऱ

֊চԺΕԸࠠࢭ࠹ᚨԺፖᄵ৫࿛ଖΔױ೚੡Ըࠠ๻ૠऱ೶

ەΔChiang[14]Ոܓش༓۶ᣂএፖֺ֊চԺ։࣫৬ዌנԫ ଡױ։࣫෺ᎵԸऱ֊চԺᑓڤΖۖ Juan[15]ٍམኙ SKD61 ᑓࠠᙓ࣍೏ຒᎵচ೶ᑇऱᙇᖗࡉףՠګءհംᠲၴΔ൶ಘ

೏ຒ֊চ೶ᑇհ່ࠋᙇᖗΖطאՂհ֮᣸ڃ᥽Δ܂ृ࿇෼

ഏփ؆ৰ֟ᖂृڇԸࠠ༓۶ߡ৫ፖ֊চࢤ౨հᣂএထᕠΖ ءઔߒڶᣂऱݾ๬໴ܫΔԸࠠ༓۶೶ᑇኙ֊চࢤ౨հ ᐙ᥼Δ༉ഏ؆೏ຒԸࠠ፹ທ೸ۖߢΔਢࠡֆ׹ૹ૞ऱ

Know-How

Δۖഏփ೏ຒԸࠠ፹ທ೸Δঞ༓׏޲ڶ৬ዌڼ

ݾ๬ᇷறΖ

ʷȮAbductive ℐ⭰

ڇᒔࡳൣउՀΔࠉᖕԫ౳ංᓵ଺෻֗ॣࡨࠃٙංᓵ൓

ࠩᄅऱࠃٙհංᓵֱڤጠ੡ Deductive ංᓵΖլመΔኔᎾ

ംᠲհංᓵΔᆖൄਢڇլᒔࡳհणउՀၞ۩ΖڂڼΔڇլ ᒔࡳणउՀΔࠉᖕԫ౳ංᓵ଺෻֗ॣࡨࠃٙၞ۩ංᓵא൓

ࠩ ᄅࠃٙ հං ᓵֱऄ ঁ๯ ጠ੡ Abductive ංᓵ[16] Δ

Abductive

ጻሁਢᆖط Abductive ංᓵࢬ৬مհጻሁΖ࿨

࣠ΔAbductive ጻሁբ๯ৰڶயچᚨشڇᓤᠧᙁנߓอհቃ

ྒྷΖ

ڇ Abductive ጻሁխΔᓤᠧߓอ٣๯։ᇞګৰ՛ۖ១

໢հڻߓอΔྥ৵ܓشڍႈڤࠤᑇᆏរิګ๺ڍլٵᐋ

్ΖٵழΔᙁԵ᧢ᑇՈ๯։ิ৵ᙁԵٺଡࠤᑇᆏរၞ۩ዝ

(3)

ߧ 1 ㋧Ⳍӡԇ૪㊹Խడ෼ഐ

ጩΔא৬ዌ Abductive ጻሁΔڇ৬ዌ Abductive ጻሁழΔଈ ٣ؘᏁ૞ڶᙁԵࡉᙁנհᇷற஄Δྥ৵ܓشቃྒྷֱؓᎄ஁

(Predicted Square Error, PSE)

ऄঞ۞೯ขس່ࠋጻሁ࿨ዌ

[17]

ΔPSE ऄঞհഗء଺෻ਢᕣױ౨ᙇᖗ壄ᒔۖլᓤᠧհ ጻሁΖPSE ץܶࠟଡႈؾΔܛ

KP FSE

PSE= + ₍₁₎

ڇڼΔFSE ਢ಻ٽΰfitαಝᒭᇷறհጻሁऱֱؓ݁ؓ

ᎄ஁ΔKP ੡ጻሁհᓤᠧᡕፆଖ (complex penalty)Δאֱ࿓

ڤ।قګ

N CPM K

KP ^p

2σ 2

×

= ₍₂₎

ڇ ڼ Δ CPM ੡ ᓤ ᠧ ᡕ ፆ ڂ ՗ (complex penalty

multiplier)

ΔK ੡ጻሁխհএᑇᑇؾΔN ੡ಝᒭᇷறհᑇ

ؾΔ

^σ^p²

੡ᑓڤڇছԫଡቃྒྷհᎄ஁᧢ฆᑇΖ

ࠉᖕֱ࿓ڤΰ1αΔFSE հଖყ՛ழ fitting հ壄ᒔ৫ᄎ ყ೏ΖຏൄΔყᓤᠧհጻሁΔᚨᕣױ౨྇՛࣍ FSE հଖΔ ང؁ᇩᎅΔ૞ᕣױ౨ᏺՕ KP հଖΖڂڼΔڇጻሁٽګࡉ

ေ۷መ࿓խΔ່ࠋ Abductive ጻሁਢࠠڶ່՛ऱ PSE ଖհ ጻሁΖ੡Աࠌጻሁࠠڶለࠋհ壄ᒔ৫ΔڇՀ٨հጻሁٽګ խΔח CPM հଖ੡ 0.01Ζ

ɿȮ૪㊹⎞ Abductive ℐ⭰೘ᐉ

ءઔߒਢאᑓࠠᙓ (SKD61) ੡ՠٙޗறΔࠀא࠰ᔲ ֆ׹੡ءઔߒ௽ܑسขऱ೏ຒףՠشԸࠠ (ٵԫऴஉႽᏗ Ը) լٵऱԸࠠ༓۶ݮणΔኙՠٙ೚೏ຒᎵচףՠΔྥ৵ ܓشضՑڤऴٌ।೚ኔ᧭๻ૠࡉอૠ։ֱ࣫ऄΔאᛧ൓ױ ᔾऱኔ᧭ᑌءរΔࠀ೚֊চࢤ౨։࣫Ζ

⠧ɺ ➦ᅩ⤑Ȯᘍ׿⤑Ȯㇷめ⤑

೶ᑇ

ߡ৫ ᝅඝߡ ऄٻߡ 塒Ꮌߡ

՛ 20ш 5ш 7ш խ 30ш 6ш 8ш

Օ 40ш 7ш 9ш

ߧ 2 ӝңಂ̬ഐᨊ

1.

㋧Ⳍӡԇ૪㊹

ݺଚࢬࠌشٰᖻ B8 ী೏ຒጵٽףՠխ֨ᖲΰ22000

rpm

Δ22hpα೚೏ຒኔ᧭ΔۖࢬࠌشऱၦྒྷᏚᕴ੡ Olympus ΰSTM-BDZαՠࠠ᧩პᢴΔ।૿ษ৫ᔚኢݮणྒྷࡳᕴ ΰSurfcorder SEF-3500αΔԸࠠ೯ؓᘝᖲΰHaimer TD-99αΖ

ءઔߒ׌૞ਢಾኙԫጟᑓࠠᙓၞ۩ԫߓ٨ઌٵ֊চය

ٙऱլٵԸࠠ༓۶ݮणհ೏ຒףՠኔ᧭Δۖᖞଡ֊চኔ᧭

ൣݮقრڕቹ 1Ζڇኔ᧭ຝٝΔᙇᖗऱᇢ᧭᧢ᑇڶೡՍፖ ጤՍऱ塒Ꮌߡ (clearance angle)Εऄٻߡ (rake angle) ֗ᝅ ඝߡ (helical angle)Δޢԫ᧢ᑇ଺ঞՂ೶ەࠡԫ౳ᄐ੺ൄش հԸࠠߡ৫Δ࠷ࠡՂՀૻհ᧢֏ᒤ໮փאՕΕխΕ՛Կၸ

᧢ၦၞ۩ኔ᧭๵ቤΔኔ᧭๵ቤհֽᄷᑇڕ।ԫΔԸࠠ༓۶ ݮणقრڕቹ 2 ֗ቹ 3Δࠀჸ಻๻ࡳऱ֊চයٙၞ۩ޢԫ

ႈ֊চᇢ᧭Δၦྒྷףՠ૿ऱ।૿ษᜋ৫ፖԸᆮᗣ౛ၦΖԸ ᆮᗣ౛ਢᐙ᥼Ըࠠ֊চࢤ౨ڕ।૿ษᜋ৫Ε֊চ౨Ժ…࿛

հ׌૞ڂైΔՈਢܒឰԸࠠኂࡎհૹ૞ਐᑑΔۖԸᆮᗣ౛

ၦਢ࠷ڕቹ 4 ࢬق AΕBΕCΕDΕEΕFΕGΕH ࿛Զរऱ

ؓ݁ଖΖڇࠌ

φ^{8 mm}

ጤᎵԸΔ4 ՍႽᏗԸΰ0.5 Rα׌ၗ᠏

ຒሒ 20000 rpmΔ֊চ෡৫ 1 mmΔၞ࿯ຒ৫ 0.1 mm/ՍΔ ೡٻ֊চ෡৫ 0.5 mmΔԸࠠ overhang ੡ 20 mm ၞ۩೏ຒ

֊চףՠኔ᧭Δၦྒྷ।૿ษᜋ৫ழ๻ࡳଖΔcutoff ݺଚ๻

ࡳ 0.8Δspeed ၦྒྷຒ৫๻ࡳ੡ 0.05Δlength ၦྒྷ९৫๻ࡳ

੡ cutoff × 5Ζၞ۩Ըࠠ೯ؓᘝீإΔ׌ၗ᠏ຒ 20000 ᠏ G ଖݺଚ๻ࡳ੡ 2.5ΔࠀᙇᖗԸஆ໢ԫؓ૿ࠐၦྒྷ೯ؓᘝΔࠌ شհԸஆ੡ HSK 63a ীΖ௅ᖕኔ᧭๵ቤ೚ݙ೏ຒ֊চףՠ ኔ᧭Δ൓ࠩऱኔ᧭࿨࣠ᑇᖕڕ।ԲࢬقΖݺଚ࿇෼ڇ๵ቤ ኔ᧭ऱԸࠠ༓۶ݮणኙ೏ຒ֊চףՠ৵ऱ।૿ษᜋ৫ᐙ᥼

լՕΔၦ൓ֽؓၞ࿯ֱٻऱษᜋ৫ଖ Ra પڇ 0.10 µmΔি

ऴၞ࿯ֱٻ।૿ษᜋ৫ଖ Ra પڇ 0.15 µmΖ

High frequency

main spindle SET CA

CNC controller

Feed directione Tool

Zig tool path

Workpiece

Table

ၗٻ塒Ꮌߡ

ၗٻᠦᎼߡ

ၗٻ֊চߡ

(4)

உٻ֊চߡ உٻ塒Ꮌߡ

உٻᠦᎼߡ

F B

C G

D H A E E

flank werar

Normalizer First layer

Input RA Input CA Input HA Input CA Input RA

Double 1 Triple 1 Double 2 U Output CT Second

layer

Third layer Unitizer

RA:Rake angle CA:Clearance angle HA:Helical angle CT:Cutting time y01

y₀₂ y03

y02

y01

y21 y11 y31

ߧ 3 ӝңಂ̬ഐᨊ

ߧ 4 Ὁ⺊ӝӝ⌸ḇ≩⸇⸇ᛵ㔄

ߧ 5 ㅷᛵӝңಂ̬⤑ಙ᳈ଃᅠӝңḇ≩ʠ Abductive ℐ⭰⳥ᾰᑁೣ

2. Abductive

ℐ⭰೘ᐉ

ല।ԫऱኔ᧭ᑇᖕ܂੡ Abductive ሁऱಝᒭᇷறΔח

CPM

੡ 0.01Δۖڇጻሁٽګࡉေ۷መ࿓խ່ࠋ Abductive ጻሁਢࠠڶ່՛ऱ PSE ଖհጻሁΔঞေ۷ٺጟԸࠠ༓۶ݮ णၞ۩೏ຒ֊চ SKD61 ᑓࠠᙓழऱԸࠠᗣ౛ቃྒྷᑓڤऱ

Abductive

ጻሁ۞೯ٽګΔڕቹ 5 ࢬقΖ່ࠡึᙁנ࿨࣠ܛ

੡Ըࠠᗣ౛ቃྒྷᑓڤհ Abductive ጻሁڍႈڤΔٺᆏរհ

ֱ࿓ڤڕॵᙕΖ

ٵழലኔ᧭ᇷற։ܑאլٵऱԸࠠߡ৫ፖԸࠠኂࡎ

(

֊চழၴ) հᣂএΔ։ܑאլٵհԸࠠߡ৫੡ᖩၗΔԸࠠ

ᗣ౛੡᜕ၗΔڇլٵ֊চයٙՀհᣂএቹᢄ፹ګΔא೚੡

ၞԫޡհ։࣫ፖܒឰΖ

߈Ȯ⃌ኞ⎞⤽⧄

ءઔߒආشኔ᧭๻ૠऄհ٤ڂ՗ֱڤ೚ኔ᧭๵ቤࡉอ ૠ։ֱ࣫ऄΔאᛧ൓ױᔾऱኔ᧭ᑌءរΔࠀ೚֊চࢤ౨։

࣫Ζ৬ዌԫ୚ݙᖞ೏ຒԸࠠऱ༓۶೶ᑇኙ֊চࢤ౨ᐙ᥼հ

։࣫ᑓڤΔױ༼ࠎഏփԸࠠ፹ທ೸ڇၲ࿇๻ૠՂઌᅝૹ૞

ऱݾ๬ Know-HowΔۖ፹ທנ೏ࢤ౨ऱഏข೏ຒ֊চشऱ ԸࠠΖݺଚ׌૞ਢ։࣫Ըࠠ༓۶ݮणխऱ塒ᎼߡΕऄٻߡΕ ᝅඝߡ࿛ߡ৫հ᧢֏ኙ೏ຒףՠழհ֊চࢤ౨ऱᐙ᥼Δ௅

ᖕ।Բऱኔ᧭࿨࣠ᑇᖕូ౏ᖞ෻ڕቹ 6Εቹ 7Εቹ 8Ζ طቹ 6 հቹী᝟ႨࢬقΔڇ೏ຒ֊চᑓࠠᙓ SKD61 ޗறழΔጙ֏᠚Ըࠠ TiA1N ᝳᐋΔᝅඝߡڇ 30шፖ 40ш հၴڶለړऱ֊চࢤ౨ΔܛለࠋऱԸࠠኂࡎΖٵᑌطቹ 7 ࢬ։قױवΔڇٵԫଡ೏ຒ֊চයٙᛩቼՀΔ֊চᑓࠠᙓ

SKD61

ޗறழΔጙ֏᠚ᝳ TiA1N ጤᎵԸΔ塒Ꮌ՛ΰ

7⁰

α

ڶለړऱ֊চࢤ౨Ζۖطቹ 8 հቹীࢬقঞܫقݺଚΔڇ ٵԫଡ೏ຒ֊চයٙᛩቼՀΔ֊চᑓࠠᙓ SKD61 ޗறழΔ ጙ֏᠚ᝳ TiA1N ጤᎵԸΔऄٻߡՕΰ

7⁰

αڶለࠋऱ֊চࢤ ౨Ζ

੡᧭ᢞٺጟԸࠠ༓۶ݮणၞ۩೏ຒ֊চ SKD61 ᑓࠠ

ᙓழऱԸࠠᗣ౛ፖ Abductive ጻሁቃྒྷᑓڤऱᄷᒔࢤΔݺ ଚലኔ᧭ᇷறፖቃྒྷ࿨࣠ᢄ፹ڇቹ 9 ፖቹ 10Δᒵය।قቃ ۷࿨࣠ۖរಖᇆ (ᑑق) ।قኔ᧭ଖΔطቹխױ൓वኔ᧭

ଖፖቃྒྷଖࠟထઌᅝ൷२Ζ

ڂ ڼ ௅ ᖕ ऱ ኔ ᧭ ࿨ ࣠ ೚ ੡ ಝ ᒭ ऱ ᑌ ء រ Δ ຘ መ

Abductive

ጻሁऱᖂ฾መ࿓Δܛױ߰ຒ৬ዌנေ۷Ըࠠ༓۶

ݮण೶ᑇፖԸࠠᗣ౛ऱᑇᖂᣂএᑓڤΖࠌشृ׽૞ᙁԵ塒 ᎼߡΕऄٻߡΕᝅඝߡፖԸࠠኂࡎ (֊চழၴ) հྒྷᇢᇷ ற۟ቹ 5 ऱጻሁᑓڤխΔঁױمܛေ۷נԸࠠऱԸᆮؓ݁

ᗣ౛ၦΖࢬאڼᑓڤঁױ༼ࠎഏփԸࠠ፹ທ೸ڇၲ࿇๻ૠ Ղઌᅝૹ૞ऱݾ๬ Know-HowΖʳ

ʽȮ⃌ ⧄

ൕኔ᧭࿨࣠ូ౏։࣫൓वڇ೏ຒ֊চףՠ SKD61 ᑓ

ࠠᙓழΔጙ֏᠚ᝳ TiA1N ऱጤᎵԸࠡᝅඝߡڇ 30ш۟ 40шΕ 塒Ꮌߡ 7шΕऄٻߡ 7шڶለࠋऱ֊চࢤ౨Ζݺଚലኔ᧭࿨

࣠৬ዌګऱԸࠠᗣ౛ቃྒྷᑓڤΔ׽૞១໢ᙁԵ塒ᎼߡΕऄ ٻߡΕᝅඝߡፖԸࠠኂࡎ (֊চழၴ) ঁױمܛ൓ࠩԸᆮ ᗣ౛Δױ༼ࠎഏփԸࠠ፹ທ೸ڇၲ࿇๻ૠՂઌᅝૹ૞ऱ೶

ەᇷಛΖ

⦒ ⨀

ء֮܂ृტ᝔ഏઝᄎ NSC92-2516-S-150-002-ૠቤ֭

਍Δࠌءઔߒூ൓אႉܓݙګΔء֮܂ृࠀტ᝔᎓೜⺎Ε

ܦࡲᙤ࿛ٵᖂڇ೏ຒ֊চኔ᧭Ղऱ࠰ܗΖ

(5)

⠧ʷ ૪㊹⣳Ԭ᱿ӝңಂ̬ഐᨊʠ㋧ⳌӡԇԽడ૪㊹⃌ኞ

Cutting time _ΰmin_α Cutting time _ΰmin_α

Test number

Helical angle

Rake angle

Clearance angle

Flank wear _ΰmm)

Test number

Helical angle

Rake angle

Clearance angle

Flank wear _ΰmm 0 9.3 18.51 27.72 36.93 0 9.23 18.56 27.52 1 40 7 9

0 0.0894 0.1268 0.1705 0.2332

15 30 5 8

0 0.11 0.15 0.1945 0 9.33 18.68 27.91 0 9.25 18.48 27.7 2 40 6 9

0 0.1252 0.152 0.2128

16 20 7 8

0 0.095 0.163 0.2235

0 9.33 18.7 28.03 0 9..3 18.6

3 40 5 9

0 0.1063 0.157 0.245

17 20 6 8

0 0.132 0.212

0 9.2 0 9..3 18.63

4 30 7 9 0 _ഽԸ

18 20 5 8

0 0.1279 0.1923

0 9.2 18.42 27.65 0 9..23 18.46

5 30 6 9

0 0.1006 0.1526 0.2212

19 40 7 7

0 0.1497 _ഽԸ

0 9.56 19.08 28.52 0 9..3 18.65 27.95 6 30 5 9

0 0.1026 0.1677 0.2104

20 40 6 7

0 0.0866 0.1371 0.1971 0 9.25 18.45 27.65 0 9.3 18.63 27.96 7 20 7 9

0 0.11 0.14 0.214

21 40 5 7

0 0.1133 0.1583 0.206 0 9.38 18.72 27.93 0 9.16 18.5 27.73 8 20 6 9

0 0.104 0.174 0.243

22 30 7 7

0 0.135 0.1804 0.23

0 9.3 18.63 0 9.21 18.45 27.75

9 20 5 9

0 0.1055 0.195

23 30 6 7

0 0.102 0.1685 0.222

0 9.21 18.46 27.64 0 9.3 18.6 27.93

10 40 7 8

0 0.0776 0.1312 0.1838

24 30 5 7

0 0.087 0.131 0.2508

0 9.26 18.56 27.86 0 9.35 18.65

11 40 6 8

0 0.1106 0.1692 0.247

25 20 7 7

0 0.126 0.202

0 9.3 18.63 27.96 0 9.5 18.73

12 40 5 8

0 0.102 0.168 0.253

26 20 6 7

0 0.11 0.172

0 9.23 18.39 27.64 0 9.33 18.63

13 30 7 8

0 0.091 0.1403 0.218

27 20 5 7

0 0.128 0.2 0 9.23 18.56 27.82

14 30 6 8

0 .0132 0.17 0.2375

(6)

0.50

0.40

0.30

0.20

0.10

0.00

Flank wear (mm)

Clearance 9ĄǴRake 5ĄǴHelical 40Ą Clearance 9ĄǴRake 5ĄǴHelical 30Ą Clearance 9ĄǴRake 5ĄǴHelical 20Ą

0.00 10.00 20.00 30.00 0.50

0.40

0.30

0.20

0.10

0.00

Flank wear (mm)

Clearance 9ĄǴRake 6ĄǴHelical 20Ą Clearance 9ĄǴRake 6ĄǴHelical 40Ą Clearance 9ĄǴRake 6 ĄǴHelical 30

0.00 10.00 20.00 30.00 0.50

0.40

0.30

0.20

0.10

0.00

Flank wear (mm)

0.00 10.00 20.00 30.00

0.50

0.40

0.30

0.20

0.10

0.00

Flank wear (mm)

0.00 10.00 20.00 30.00 0.50

0.40

0.30

0.20

0.10

0.00

Flank wear (mm)

0.00 10.00 20.00 30.00 0.50

0.40

0.30

0.20

0.10

0.00

Flank wear (mm)

0.00 10.00 20.00 30.00 Cutting time (min)

Cutting time (min)

Cutting time (min) Cutting time (min)

Cutting time (min)

0.50

0.40

0.30

0.20

0.10

0.00

Flank wear (mm)

0.00 10.00 20.00 30.00 0.50

0.40

0.30

0.20

0.10

0.00

Flank wear (mm)

0.00 10.00 20.00 30.00 0.50

0.40

0.30

0.20

0.10

0.00

Flank wear (mm)

0.00 10.00 20.00 30.00 0.50

0.40

0.30

0.20

0.10

0.00

Flank wear (mm)

0.00 10.00 20.00 30.00 0.50

0.40

0.30

0.20

0.10

0.00

Flank wear (mm)

Clearance 9ĄǴRake 7ĄǴHelical 40Ą Clearance 8ĄǴRake 7ĄǴHelical 40Ą

0.00 10.00 20.00 30.00 40.00 0.50

0.40

0.30

0.20

0.10

0.00

Flank wear (mm)

0.00 10.00 20.00 30.00

Cutting time (min)

ߧ 6 ʃ׺➦ᅩ⤑ଃӝңḇ≩ʠഛㅨ

ߧ 7 ʃ׺ㇷめ⤑ଃӝңḇ≩ʠഛㅨ

(7)

Flank wear (mm)

0.50

0.40

0.30

0.20

0.10

0.00

Clearance 8ĄǴRake 7ĄǴHelical 40Ąʳ Clearance 8ĄǴRake 6ĄǴHelical 40Ąʳ Clearance 8ĄǴRake 5ĄǴHelical 40Ą

0.00 10.00 20.00 30.00

Flank wear (mm)

0.00 10.00 20.00 30.00 0.50

0.40

0.30

0.20

0.10

0.00

0.50

0.40

0.30

0.20

0.10

0.00

Flank wear (mm)

0.00 10.00 20.00 30.00 0.50

0.40

0.30

0.20

0.10

0.00

Flank wear (mm)

Clearance 7ĄǴRake 6ĄǴHelical 40Ąʳ Clearance 7ĄǴRake 5ĄǴHelical 40Ą

0.00 10.00 20.00 30.00 0.50

0.40

0.30

0.20

0.10

0.00

Flank wear (mm)

0.00 10.00 20.00 30.00 40.00 0.50

0.40

0.30

0.20

0.10

0.00

Flank wear (mm)

0.00 10.00 20.00 30.00 Cutting time (min)

Cutting time (min)

Clearance 7 Rake 7Ą(measured)ʳ Rake 6Ą(measured)ʳ Rake 5Ą(measured)ʳ Rake 7Ą(predicted)ʳ Rake 6Ą(predicted)ʳ Rake 5Ą(predicted)

Cutting time (min)

20.00 30.00 40.00 36.00

32.00

28.00

24.00

20.00

16.00

Helical angle (໢ۯ : ৫)

Cutting time (min)

20.00 30.00 40.00 36.00

32.00

28.00

24.00

20.00

16.00

Cutting time (min)

20.00 30.00 40.00 36.00

32.00

28.00

24.00

20.00

ߧ 8 ʃ׺ᘍ׿⤑ଃӝңḇ≩ʠഛㅨ

ߧ 9 ӠӲߗહ߱ʃ׺᱿ㇷめ⤑ʠʁ⩐ջᘍ׿⤑⎞➦ᅩ⤑Ŋ Abductive ℐ⭰ㅷᛵᑁೣُ૪㊹ϊҢӝңउلʠᕗⰱ

ߧ 10 ӠӲߗહ߱ʃ׺᱿ᘍ׿⤑ʠʁʠʁ⩐ջ➦ᅩ⤑⎞➦ᅩ⤑ŊAbductive ℐ⭰ㅷᛵᑁೣُ૪㊹ϊҢӝңउلʠᕗⰱ

Rake 5 Clearance 9Ą(measured)ʳ Clearance 8Ą(measured)ʳ Clearance 7Ą(measured)ʳ Clearance 9Ą(predicted)ʳ Clearance 8Ą(predicted)ʳ Clearance 7Ą(predicted)

Cutting time (min)

20.00 30.00 40.00 36.00

32.00

28.00

24.00

20.00

16.00

Cutting time (min)

20.00 30.00 40.00 36.00

32.00

28.00

24.00

20.00

16.00

Cutting time (min)

20.00 30.00 40.00 36.00

32.00

28.00

24.00

20.00

(8)

א≙ᄽ᪇

1. Schulz, H., “High-speed Machining,” CIRP Annals – Manufacturing Technology, Vol. 41, pp. 637-643 (1992).

2. Schulz, H., and Hock, St., “High-speed Milling of Dies and Moulds – Cutting Conditions and Technology,” CIRP Annals – Manufacturing Technology, Vol. 44, pp. 35-38 (1995).

3. Thusty, J., “High-speed Machining,” CIRP Annals – Manufacturing Technology, Vol. 42, pp. 733-738 (1993).

4.

▼ൠໞŊኚᆙ⏦ُづહબŊȵሱञቨᅆẼぜ᪓ᣅᲿᐻʠ ᑁң׶⸉㋧Ⳍ⺊ԇאᄲⶪ⇦ȶŊὮ 17 ଢᑨፋడỄᶇ⤽

ሳŊञ┤ञણŊὮ 419-423 ㅪ (2000).

5. Fuh-Chyun Tang, and Chih-Chieh Lin, “High-speed Machining of Hardened SKD61 Tool Steel Using TiALN Coated Cemented Tungsten Carbide Tooling,”

Ὦ֓ɼଢ ᑨፋడỄᶇ⤽ሳŊञ┤ञણŊὮ 759-766 ㅪ (2000).

6.

ಽ;゛Ŋȵ⺭׶⸉㋧Ⳍӡԇଃ⠧ㄇ⁤ಙഛㅨʠᶇἄȶŊ

ᷟं⧄ᄽŊʑᔌञણŊ݄∑ (1996).

7.

ኚᙜ⎄Ŋȵ㋧ⳌὉ⺊ԇ Ti-6Al-4V ⹃׶⸉ȶŊᷟं⧄ᄽŊ שᢕञણŊשռ (1998).

8.

೺᥾ⱇŊ⥓ᅺᏳŊᄑሷቢُづҴᄽŊȵʏ⊓ೣᑨፋడң ᑨʠᱹଭȶŊᑨፋడᏈグ⦒Ŋ3 ሶᦹŊpp.104-166 (2000).

9.

㓳㐓ЂŊȵ㋧ⳌԽడʠᱹଭ⎞⬹՛ȶŊᑨፋడᏈグ⦒Ŋ

3

ሶᦹŊpp.209-212 (2000).

10. Paro, J., Nieminen, I., Kauppinen, V.,” High-speed Machining in Tooling Production,” Journal of Materials process Technology, Vol. 52, pp. 27-34 (1995).

11. Shatla, M., Altan, T., “Analytical Modeling of Drilling and Ball End Milling,” Journal of Materials process Technology, Vol. 98, pp. 125-133 (2000).

12. Engin, S., Altintas, Y., “Mechanics and Dynamics of General Milling Cutters. Part I: Helical End Mills,”

International Journal of Machine Tools and Manufacture, Vol. 41, pp. 2195-2212 (2001).

13. Tugrul Ozel, Taylan Altan, “Process Simulation using Finite Element method-Prediction of Cutting Forces, Tool Stresses and Temperatures in High-Speed Flat End Milling,” International Journal of Machine Tools and Manufacture, Vol. 40, pp. 713-738 (2000).

14. Shiuh-Tarng Chiang, Chung-Min Tasi, An-Chen Lee,

“Analysis of Cutting Forces in Ball-End Milling,” Journal of Materials process Technology, Vol. 47, pp. 231-249 (1995).

15. Juan, D. J., Yu, S. F., and Lee, B. Y., “The Optimal Cutting-parameter Selection of Production Cost in High Speed Machining for SKD61 Tool Steels,” International Journal of Machine Tools and Manufacture, Vol. 43, pp. 679-686. (2003).

16. Peirce, C., Abduction and induction, Philosophical Writing of Peirce, ed. by Buckler, Dover, NY, USA (1955).

17. Barron, A. R., Predicated Square error: a criterion for automatic model selection, in self-Organizing Methods in Modeling: GMDH Type Algorithms, Farlow, S. J., Ed.

Marcel-Dekker, NY, USA (1984).

え⻞

Appendix ( i ) normalizer : 1.y₀₁=−7.21+1.2Ra 2.y02=−9.61+1.2Ca 3.y₀₃

= −

3.07

+

0.107Ha

( ii ) double node :

1.

02 01 2

02

2 01 02

01 21

401 . 0 105 . 0

164 . 0 48 . 0 377 . 0 259 . 0

y y y

y y

+ +

+

−

=

2.y₃₁=1.07y₁₁−0.127y₀₁

(iii) triple node:

1.

3 03 3

21 02 03 21 02 03 02

21

03 21 2

03 2

21 03 21 11

241 . 0 47 . 4 314

. 0 248 . 0 39 . 2

394 . 0 163 . 0 09 . 3 03 . 1 16 . 2 333 . 0

y y

y y y y y y

y

y y y

y y y y

−

− +

+

− +

+ +

−

=

(iv) unitizer : 1.CT =24+3.68y₃₁

2006

ڣ 09 ִ 12 ֲʳ گᒚ

2006

ڣ 09 ִ 26 ֲʳ ॣᐉ

2008