行星式運動結合二維振動輔助磁力研磨設備開發與應用

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研究生：	李宜勳 Yi-hsun Lee
論文名稱：	行星式運動結合二維振動輔助磁力研磨設備開發與應用 Development and Implementation of Equipment on Planetary Motion Combined with Two-Dimensional Vibration-Assisted Magnetic Abrasive Finishing
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：	2015
畢業學年度：	103
語文別：	中文
論文頁數：	144
中文關鍵詞：	磁力研磨
外文關鍵詞：	MAF
相關次數：	點閱：8 下載：0
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本研究以自行開發的新型磁力研磨法為研究主軸，應用行星式運動結合二維振動輔助磁力研磨(PM-2DVAMAF)的機制於不鏽鋼材料上進行拋光。
首先探討二維振動輔助對於MAF的影響，以及針對各加工參數的特性進行研究。結果顯示，二維振動輔助磁力研磨(2D VAMAF)的機制可以使工件的表面與磁極的旋轉加工方向形成緻密的交叉加工痕跡，因此可以提高研磨效率與精度。實驗證明，振動輔助磁力研磨加工在最適參數組合下，能於5分鐘內有效改善不鏽鋼表面粗糙度由Ra 0.13μm改善至0.03μm，改善率達77%。
進一步利用行星式運動結合二維振動輔助磁力研磨，其主要目的是利用行星齒輪機構自轉與公轉的特點，結合二維振動輔助，使工件表面形成高密度的交叉紋路。結果顯示，在最適當的參數組合下，能於12.5分鐘內有效改善不銹鋼表面粗糙度由Ra0.16μm降低至0.032μm，改善率為80%。
最後探討二維振動輔助磁力研磨配合羊毛氈拋光墊，對於不鏽鋼表面粗糙度改善之情況。結果顯示，在最適當的參數組合下能在5分鐘內有效改善不銹鋼表面粗糙度由Ra0.14μm降低至0.03μm，改善率為78.57%。

This study develops a new surface polishing approach by combining planetary motion (PM) with two-dimensional vibration-assisted magnetic abrasive finishing (PM-2DVAMAF). Planetary motion involves both rotation and revolution, thus generating radial acceleration, which strengthens the normal force exerted on the workpiece surface, and in turn enhances the cutting power of the abrasives and their polishing performance.
First, investigate adding the two-dimensional vibration-assisted influence on the processing of MAF. From experimental results, 2D VAMAF can effectively increase the polishing efficiency of MAF and improve surface quality. In addition to MAF by steel particles and SiC abrasives, dense intersecting machining paths on the workpiece are also formed under vibration assistance, thus contributing to better polishing efficiency and precision. With 5-min 2D VAMAF under optimal parameter combination, the surface roughness of a stainless steel SUS304 workpiece can be reduced from 0.13 μm to 0.03 μm, an improvement of 77%.
Further discussion PM-2DVAMAF, PM results in uniform, intersecting and closely packed polishing paths, which contribute to better surface quality within a shorter processing time. Experimental results reveal that 12.5-min PM-2DVAMAF under optimal parameter combination can reduce surface roughness of a stainless steel SUS304 workpiece from 0.16 μm to 0.032 μm, an improvement of 80%.

摘    要................................................................................................................i

Abstract.................................................................................................................ii

謝    誌.............................................................................................................. iii

目    錄.............................................................................................................. v

圖 目 錄...............................................................................................................x

表 目 錄............................................................................................................. xiii

第一章    緒論.........................................................................................................1
   1-1 研究動機.................................................................................................1
   1-2 文獻回顧.................................................................................................4
       1-2-1探討探討振動結合磁力研磨文獻...............................................4
       1-2-2探討各加工參數對表面粗糙度與材料移除率文獻...................5
       1-2-3探討磁性複合液體文獻……………………………...................5
1-2-4探討磁力研磨複合加工法文獻……………………...................6
1-2-5探討磁極設計文獻.......................................................................6
1-2-6田口實驗計畫法……………………………………...................6
   1-3 研究目的...............................................................................................9
   1-4 本論文之構成.......................................................................................12
第二章 實驗原理...............................................................................................15
   2-1 磁力研磨拋光之加工原理...................................................................15
   2-2 磁性磨粒之切削加工機制...................................................................19
   2-3 行星齒輪系……………………………………………….…………..20
   2-4 田口品質工程…………………………………………….…………..21
        2-4-1田口方法概述…………………………………………………21
        2-4-2 實驗設計流程………………………………………………….21
        2-4-3決定目標特性…………………………………………………23
        2-4-4 直交陣列表……………………………………………………23
        2-4-5 訊號/噪音比……………………………………………………24
        2-4-6 變異數分析……………………………………………………25
2-4-7 驗證實驗……………………………………………………….26
第三章 二維振動輔助磁力研磨之設備開發與應用…………….………......27
   3-1 前言.......................................................................................................27
   3-2 實驗設備與方法...................................................................................29
       3-2-1 實驗設備....................................................................................29
       3-2-2 振動輔助機構設計....................................................................31
       3-2-3 實驗材料與方法........................................................................32
   3-3 結果與討論...........................................................................................36
       3-3-1二維振動輔助對於磁力研磨的影響………………………….36
       3-3-2 2D VAMAF的因子效果回應分析.........................................  ...41
            3-3-2-1田口正交實驗…………………………………………41
3-3-2-2變異數分析與F檢定………………………..………..42
       3-3-3驗證實驗…………………………………….............................44
       3-3-4加工參數對表面粗糙度的影響.................................................47
3-3-4-1  SiC粒徑對表面粗糙度的影響………..…...……..…47
3-3-4-2 加工間距對表面粗糙度的影響……….…………  .…48
3-3-4-3 振動頻率對表面粗糙度的影響………………...… .....49
3-3-4-4  SiC重量對表面粗糙度的影響………...……….... …50
3-3-4-5 加工液重量對表面粗糙度的影響……………...……52
   3-4 結論.......................................................................................................54
第四章 行星式運動結合二維振動的新型研磨法之研究...............................55
4-1 前言.......................................................................................................55
4-2 實驗設備與方法...................................................................................57
       4-2-1 行星機構設計與開發................................................................57
       4-2-2 PM-2DVAMAF及MAF的運動方式與軌跡........................  ..60
       4-2-3實驗方法與材料.........................................................................63
   4-3 結果與討論...........................................................................................65
       4-3-1 PM-2DVAMAF最佳參數組合……...……......................…….65
4-3-1-1田口正交實驗…………………………………………65
4-3-1-2變異數分析與F檢定………………………..………..66
4-3-1-3驗證實驗………………………………………………68
4-3-2行星式二維振動輔助對於磁力研磨的影響……………..……72
4-3-3加工參數對於表面粗糙度的影響……………………….……  73
4-3-3-1加工液重量對表面粗糙度的影響…………..………..73
4-3-3-2鋼砂重量對表面粗糙度的影響…………..…………..74
4-3-3-3鋼砂粒徑對表面粗糙度的影響…………..…………..76
4-3-3-4振動頻率對表面粗糙度的影響…………..…………..77
4-3-3-5振幅對表面粗糙度的影響…………..………………..78
4-3-3-6磁極轉速對表面粗糙度的影響…………..…………..79
   4-4 結論.......................................................................................................81
第五章 應用可撓式磁力輔助拋光工具之二維振動研究…….……………..82
   5-1 前言.......................................................................................................82
   5-2 實驗設備與方法...................................................................................84
       5-2-1 磁極鋼套形狀設計....................................................................84
       5-2-2 實驗材料與方法........................................................................86
       5-2-3 實驗步驟....................................................................................89
       5-2-4 表面粗糙度之量測....................................................................89
   5-3 結果與討論...........................................................................................90
       5-3-1前置實驗......................................................................................90
5-3-1-1磁極間距對粗糙度的影響............................................90
5-3-1-2拋光墊對於表面形貌的影響........................................91
      5-3-2實驗參數水準設計.......................................................................92
      5-3-3實驗結果分析……………….......................................................95
5-3-3-1 振動輔助對磁力研磨的影響.......................................95
5-3-3-2 田口正交實驗……....................................................98
5-3-3-3 變異數分析及F檢定..................................................100
5-3-3-4 驗證實驗....................................................................    102
      5-3-4加工參數對表面粗糙度的影響..................................................104
5-3-4-1實驗條件與規劃..........................................................104
5-3-4-2振動平台X方向振動頻率對表面粗糙度的影響.....105
5-3-4-3 SiC重量對表面粗糙度的影響……………………...106
5-3-4-4鋼砂重量對表面粗糙度的影響……………………..107
5-3-4-5研磨液重量對表面粗糙度的影響..............................109
5-3-4-6振動平台轉速對表面粗糙度的影響..........................111
5-3-4-7振動平台振幅對表面粗糙度的影響..........................112
5-3-4-8鋼砂粒徑對表面粗糙度的影響..................................113
5-3-4-9磁極轉速對表面粗糙度的影響..................................114
5-3-4-10加工時間對表面粗糙度的影響................................116
   5-4 結論......................................................................................................119
第六章 總結論.................................................................................................120
參考文獻...........................................................................................................122

                                

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