新型磨粒的磁力輔助螺旋研拋加工之研究｜國立中央大學博碩士論文系統

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研究生：	陳為展 Wei-Chan Chen
論文名稱：	新型磨粒的磁力輔助螺旋研拋加工之研究 A study on the application of newly-developed abrasive to magneto-assisted spiral polishing.
指導教授：	顏炳華 Biing-Hwa Yan
口試委員:
學位類別：	博士 Doctor
系所名稱：	工學院 - 機械工程學系 Department of Mechanical Engineering
論文出版年：	2014
畢業學年度：	102
語文別：	中文
論文頁數：	111
中文關鍵詞：	螺旋研拋加工、磁力研磨、磁性磨粒、不鏽鋼內圓孔、表面粗糙度
外文關鍵詞：	Spiral polishing machining, Magneto-assisted polishing, Magnetic abrasive, Inner-wall polishing, Surface roughness
相關次數：	點閱：16 下載：0
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螺旋研拋加工法是一種利用高速螺旋迴轉傳遞磨料進行拋光的技術，當螺桿高速旋轉時，磨料將順著螺桿的螺旋溝槽朝上移動，被傳動之磨料直接高速研磨接觸被加工件，運動行程較傳統磨粒流拋光方式行程長而達到表面均勻拋光作用，因本加工法之磨料具有循環作動功能，磨料成本低且消耗量少，可獲得『低成本』、『快速』且『有效率』去除毛邊、變質層等功能，達到被加工件『快速精拋』的加工效果。
本研究將磁力研磨拋光與螺旋研拋法相結合，利用磁力研磨拋光的磁力加強螺旋研拋加工時的加工力，改善游離磨料加工時加工力較弱的缺點，增進研磨拋光加工時的效果。磨粒在螺旋研拋加工法扮演舉足輕重的地位，本研究自行開發新型磁性磨粒，在磨粒表面披覆一層磁性粒子，使之具有磁性磨粒的功能，再者利用磨粒中高分子粒子的彈性，減低磨粒撞擊工件表面時所產生的撞擊能，有效吸收過大的衝擊力，減少過度加工的作用。將之應用在不鏽鋼內圓孔之表面研拋，由實驗可得在磁通量密度90mT、碳化矽粒徑4μm、矽油黏度2000mm2/s、磁性磨粒濃度60%、加工間隙0.6mm及主軸轉速4000rpm之加工參數，可於20分鐘內將表面粗糙度Ra由0.9μm大幅下降到0.0541μm ，改善率達到94%，可明顯縮短拋光時間並得到極佳的表面加工效果。

Spiral polishing mechanism is the technology of employing a high-speed turning screw rod to drive the abrasive to achieve the purpose of polishing the workpiece surface. The fast-turning screw rod drives the abrasive to move upward along the groove of the rod to keep polishing the workpiece in a recycling movement. Compared with traditional polishing methods, the long moving path of the abrasive helps achieve better polishing quality. Besides, the recycling movement of the abrasive not only effectively reduces the cost and the quantity of abrasive, but also removes the burrs in a fast, efficient, and economical way. Therefore, it is a superior method to reach good machining effect.
In this study, the magneto-assisted polishing was combined with spiral polishing mechanism. With the magnetism employed in the magneto-assisted polishing, the polishing force of the abrasive in spiral polishing was enforced and thus the polishing effect was improved. Actually, the abrasive played a crucial role in spiral polishing mechanism. In the present study, a new kind of magnetic abrasive was developed by coating each particle with a layer of magnetic particles. Moreover, the elasticity of the abrasive eased the kinetic energy generated from the polishing process on the workpiece surface, with the function of reducing the great impact during the polishing and preventing the effect of over-polishing. When this technology was applied to the polishing of the inner wall of the bore, the results of the experiment showed that with the parameter variables of magnetic flux density of 90mT, Sic size of 4μm, Silicone oil viscosity of 2000mm2/s, magneto-elastic abrasive concentration of 60%, machining gap of 0.6 mm , and the spindle revolution speed at 4000 rpm, the surface roughness (Ra) was lowered from 0.90 μm. to 0.0541 μm. in 20 minutes, at the improvement rate of 94%. The polishing time was significantly shortened and the optimal polishing effect was obtained.

摘  要    i
Abstract    ii
謝  誌    iv
目  錄    v
圖目錄    ix
表目錄    xii
第一章 緒論    1
1-1 研究背景    1
1-2研究動機與目的    2
1-3文獻回顧    4
1-4研究方法    9
第二章 混合磨料於不銹鋼內孔之螺旋研拋加工    10
2-1前言    10
2-2磨料螺旋研拋加工法    11
2-3加工特性    13
2-4實驗設備、材料與方法    16
2-4-1實驗設備    16
2-4-2實驗材料    19
2-4-3研究方法    25
2-4-3-1田口實驗計劃法    25
2-4-3-2直交陣列表    26
2-4-3-3訊號/噪音比    26
2-4-3-4變異數分析    28
2-4-3-5實驗設計規劃    29
2-5實驗流程    30
2-6結果與討論    31
2-6-1加工參數設定    31
2-6-1-1因子水準設定    31
2-6-1-2直交表配置    32
2-6-1-3因子效果回應分析    32
2-6-1-4變異數分析(ANOVA)及F檢定（F-test）    35
2-6-1-5驗證實驗    37
2-6-2表面粗糙度之參數因子分析    38
2-6-2-1磨粒大小對表面粗糙度之影響    39
2-6-2-2 SiC重量對表面粗糙度之影響    40
2-6-2-3 PS重量對表面粗糙度之影響    41
2-6-2-4矽油黏度對表面粗糙度之影響    42
2-6-2-5加工轉速對表面粗糙度之影響    43
2-6-2-6加工時間對表面粗糙度之影響    44
2-6-3材料移除量之參數因子分析    45
2-6-3-1磨粒大小對材料移除量之影響    45
2-6-3-2 SiC重量對材料移除量之影響    46
2-6-3-3 PS重量對材料移除量之影響    47
2-6-3-4矽油黏度對材料移除量之影響    48
2-6-3-5加工轉速對材料移除量之影響    49
2-6-3-6加工時間對材料移除量之影響    50
2-6-4磨料溫度之參數因子分析    51
2-6-4-1加工時間對加工溫度之影響    51
2-6-4-2加工轉速對加工溫度之影響    53
2-6-4-3磨粒粒徑對加工溫度之影響    54
2-6-4-4矽油黏度對加工溫度之影響    55
2-6-5表面研拋之效果    56
2-7結論    58
第三章 磁性熱熔膠粒應用於磁力與螺旋研拋複合加工    59
3-1前言    59
3-2磁性熱熔膠粒    60
3-3磁力輔助加工特性    61
3-4磁性熱熔膠粒應用於磁力輔助螺旋研拋加工    64
3-4-1實驗裝置    64
3-4-2實驗方法    65
3-5實驗流程    67
3-6結果與討論    68
3-6-1最小表面粗糙度之參數組合    68
3-6-2加工參數之分析    72
3-6-2-1磁通量密度對加工之影響    72
3-6-2-2磁性熱熔膠粒重量百分比對加工之影響    74
3-6-2-3矽油黏度對加工之影響    75
3-6-2-4加工間隙對加工之影響    76
3-6-3磨料黏度分析    78
3-6-3-1加工時間對磨料黏度的影響    79
3-6-3-2碳化矽重量對磨料黏度的影響    79
3-6-3-3碳化矽粒徑對磨料黏度的影響    79 
3-6-4加工參數與磨料溫度之關係    81
3-6-4-1加工時間對磨料溫度的影響    81
3-6-4-2主軸轉速對磨料溫度的影響    82
3-7結論    84
第四章 磁彈性磨粒於磁力螺旋研拋加工之研究    85
4-1前言    85
4-2磁彈性磨粒加工特性    86
4-3磁彈性磨粒    87
4-4實驗方法    91
4-5結果與討論    93
4-5-1最適加工參數組合    93
4-5-2加工參數之探討    96
4-5-2-1磁通量密度對加工之影響    96
4-5-2-2磁彈性磨粒濃度對加工之影響    98
4-5-3磨料黏度的分析    100
4-5-4磨料溫升的分析    101
4-6結論    102
第五章 總結論    103
參考文獻    105
作者簡介    110

                                

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