黏彈性磨料應用於複雜曲面的精拋技術研究｜國立中央大學博碩士論文系統

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研究生：	曾信智 Hsinn-Jyh Tzeng
論文名稱：	黏彈性磨料應用於複雜曲面的精拋技術研究 A Study of Visco-elastic Abrasive Applied to Micro Lapping Techniques for Complex Surface
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
畢業學年度：	94
語文別：	中文
論文頁數：	130
中文關鍵詞：	生醫、表面粗糙度、螺旋式磨料流動研拋、表面精修、再鑄層、黏彈性磨料、放電加工、微流道、往復式磨料流動研拋法
外文關鍵詞：	visco-elastic abrasive, micro channel, Bio-medicine, surface roughness, electric discharge machining, reciprocating abrasive flow machining, spiral abrasive flow machining, recast layer
相關次數：	點閱：21 下載：0
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3C導光板成形模具、生醫微流道、微射出模具與精密機械等複雜曲面，由於放電加工後易殘留毛邊，所形成的再鑄層散佈著微細裂紋或氣孔等缺陷，使得加工面品質變差。本論文研究重點針對複雜曲面提出改善表面品質的精拋方法。
首先開發一經濟且實用的黏彈性磨料，其次是結合磨料特性應用於往復式磨料流動研拋法進行表面精修，遂而發展一種新型螺旋式磨料流動研拋技術，藉著高速旋轉螺桿傳遞磨料，對試件表面產生極微研拋的去除效果，而獲得精細加工表面的一種超精密加工方法。經由實驗結果分析顯示，確實能有效去除放電加工所造成的毛邊或殘留不潔物，而獲得較佳的形狀精度。最後是針對內孔表面再進行螺旋式磨料流動研拋，表面粗糙度由0.23μm 大幅降至0.05μm Ra，表面有極微量的材料去除，達到快速精拋的效果。

For the complex surface products of the formed mold of 3C guide light board, the micro channel, micro inject mold of bio-medicine and the screw of precision mechanism, the deburring and recast layer in EDMed work-piece decreases the surface quality. The tiny fragments from the recast layer are likely to spread tiny cracks and produce micro blowholes. In this study, three techniques are proposed to improve the surface roughness and to achieve a high surface quality.
First, an economical and practical abrasive with visco-elastic abrasive for fine polishing was developed. A fine processed surface can be obtained and the effect of the removal of the tiny fragments can be achieved through this technique. The second technique applies the method of reciprocating abrasive flow machining to the surface, creating more characteristics of visco-elastic abrasive. Thus, the surface of the micro orifice of complex surface can be quickly and effectively polished and improved. Finally, this study develops a new method of spiral abrasive flow machining with elastic abrasive, especially suited for the complex surface. The abrasive medium removes tiny fragments and debris. It improves the initial surface roughness from 0.23µm to 0.05µm Ra. This spiral abrasive flow machining method also homogenously polishes the work-piece surface, and clearly improves the quality of finished surfaces. This technology is low cost and highly efficient.
Keywords：Bio-medicine、micro channel、electric discharge machining、recast layer、visco-elastic abrasive、reciprocating abrasive flow machining、spiral abrasive flow machining、surface roughness.

中文摘要.............................................................................................I
英文摘要....................................................................................................II
謝誌..........................................................................................................III
目錄...........................................................................................................V
圖目錄...................................................................................................IX
表目錄..................................................................................................XIII
符號說明...............................................................................................XIV
第一章 緒論..............................................................................................1
1-1研究動機與目的.........................................................................1
1-2研究背景.....................................................................................5
1-3文獻回顧.......................................................................................14
1-4研究方法...................................................................................16
1-5本論文構成...............................................................................18
第二章 黏彈性磨料開發........................................................................20
2-1前言...........................................................................................20
2-2實驗方法與研究內容...................................................................21
2-2-1黏彈性磨料之開發.................................................................21
2-2-1-1碳化矽顆粒特性................................................................22
2-2-1-2黏彈性磨料之調製...........................................................23
2-2-1-3磨料的測試與分析...........................................................26
2-2-2 往復式磨料流動研拋設備設計組裝與實驗........................30
2-2-2-1實驗設備....................................................................30
2-2-2-2模具組.....................................................................31
2-2-3往復式磨料流動研拋實驗.....................................................32
2-2-3-1實驗材料....................................................................33
2-2-3-2 實驗參數條件設定........................................................34
2-3 結果與討論...............................................................................37
2-3-1 磨料粒徑與濃度對黏度之影響........................................37
2-3-2 加工條件對黏度之影響....................................................40
2-3-3 加工條件對磨料溫度之影響............................................40
2-3-4 加工條件對表面粗糙度之影響........................................41
2-3-4-1 磨料粒徑對表面粗糙度之影響................................41
2-3-4-2 磨料濃度對表面粗糙度之影響................................45
2-3-4-3 擠製壓力對表面粗糙度之影響................................46
2-3-4-4 加工時間對表面粗糙度之影響................................47
2-3-5 磨粒於加工前、後之磨耗影響..........................................48
2-3-6 表面形狀精度之改善........................................................50
2-4 結論...........................................................................................51
第三章 往復式磨料流動研拋法應用於複雜曲面之精修....................52
3-1前言.............................................................................................52
3-2基本原理.....................................................................................53
3-3實驗方法與研究內容.................................................................56
3-3-1應用於銅管焊接內表面精修改善.......................................56
3-3-1-1 實驗方法.....................................................................56
3-3-1-2 實驗材料.....................................................................58
3-3-1-3 結果與討論.................................................................59
3-3-2應用於不鏽鋼微射出模具表面精修改善..........................62
3-3-2-1 實驗方法......................................................................62
3-3-2-2 實驗材料......................................................................63
3-3-2-3 結果與討論..................................................................65
3-4 結論.........................................................................................70
第四章往復式磨料流動研拋法應用於線放電表面精修改善..............71
4-1 前言............................................................................................71
4-2 研究方法....................................................................................72
4-2-1 田口實驗計劃法.................................................................72
4-2-2 變異數分析.........................................................................73
4-2-3 訊號/噪音比........................................................................74
4-3 實驗設備與方法........................................................................75
4-3-1 實驗方法.............................................................................75
4-3-2 實驗材料.............................................................................75
4-4 結果與討論...............................................................................76
4-4-1 實驗觀察值的S/N Ratio....................................................78
4-4-2線放電加工後之微流道形狀及表面形貌..........................79
4-4-3磨料黏度與加工時間之關係..............................................80
4-4-4加工條件對磨料溫度與表面粗糙度之關係.......................81
4-4-5表面粗糙度與磨料粒徑、濃度與擠製壓力之關係.............82
4-4-6表面形貌精修效果...............................................................85
4-5 結論...........................................................................................88
第五章 螺旋式磨料流動研磨法應用於圓管內表面拋光....................89
5-1 前言...........................................................................................89
5-2 基本原理...................................................................................90
5-2-1 螺旋研拋方法的裝置設計.................................................92
5-3 實驗方法與研究內容...............................................................93
5-3-1 實驗設備.............................................................................93
5-3-2 實驗材料.............................................................................95
5-3-3 實驗方法.............................................................................96
5-3-4 研究方法.............................................................................97
5-4 結果與討論...............................................................................98
5-4-1 加工條件對表面精度之影響.............................................98
5-4-1-1加工時間對磨料黏度之影響.........................................98
5-4-1-2磨料溫度之量測.............................................................99
5-4-1-3磨料粒徑對表面粗糙度之影響...................................101
5-4-1-4磨料濃度對表面粗糙度與材料去除率之影響...........102
5-4-1-5加工間隙對表面粗糙度之影響...................................105
5-4-1-6加工轉數對表面粗糙度與材料去除率之影響...........107
5-4-2表面研拋之效果.................................................................109
5-5 結論..........................................................................................111
第六章 總結論......................................................................................113
參考文獻................................................................................................118
作者簡介................................................................................................126

                                

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