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研究生： 李健銘
Chien-ming Lee
論文名稱： 磁力噴砂加工表面之研究
Study of Magnetic assisted sandblasting with surface processing
指導教授： 顏炳華
Biing-Hwa Yan
口試委員:
學位類別： 碩士
Master
系所名稱： 工學院 - 機械工程學系在職專班
Executive Master of Mechanical Engineering
畢業學年度： 99
語文別： 中文
論文頁數： 88
中文關鍵詞： 回歸方程式 、田口法 、表面粗糙度 、磁力噴砂
外文關鍵詞： Regression equation, Taguchi method, Surface roughness, magnetic sandblasting
相關次數： 點閱：15  下載：0 
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    • 摘 要
    噴砂主要是針對金屬表面進行破壞性的加工，利用噴射磨料對金屬表面衝擊，讓表面產生像顆粒化般的凹陷，目的是讓金屬表面能產生霧化或咬花及去除毛邊的效果。
    本研究主要是針對噴砂加工搭配磁力的手法，選用鋁材6061
    作為加工材料，藉由其材質柔軟及加工後皺褶的現象,縮短噴砂的加工時間,觀察到磁力噴砂對應表面粗糙度的加工趨勢，進一步研究磁力噴砂的加工特性及對表面加工的影響。
    首先安排前期實驗及L18實驗，將磁力噴砂的加工參數做規劃，如磁鐵擺放方式(直立or橫擺)及噴嘴角度及噴嘴距離及磁鐵距離及磁力強度及噴射強度等對加工結果(粗糙度及移除量及加工範圍)的影響。由前期實驗結果將加工時間及噴嘴角度固定，因噴嘴角度影響加工範圍及區域，對於粗糙度影響較小，加工時間則是因鋁材6061加工後會有皺褶的現象，而縮短加工時間觀察加工趨勢。而後經L18實驗結果發現噴嘴距離及磁鐵距離同為變數時，磁鐵相關的加工參數貢獻度不明顯，因此後續單因子實驗中將噴嘴角度及噴嘴距離定義為固定參數。
    由單因子實驗結果可以得到各磁鐵配置對應的粗糙度趨勢，在噴射壓力5kgf的配置下，磁力強度550mT及磁鐵距離80mm磁鐵橫擺時會有最佳的粗糙度表現，並可得到加工區域靠近磁鐵端會有較佳的粗糙度表現的結論，再輔以搭配回歸方程式所求得的方程式，則後續即可使用公式先行預估不同磁力配置下的粗糙度,有效的省去實驗次數,並加速找到較佳化結果。

    Abstract
    Sandblasting is mainly directed to destructive process on the metal surface. Use abrasive to impact the metal surface, let surface occur a depression like granulate,goal is to produce atomized metal surface etching and removal of flash effect。
    This study focuses on the sand blasting technique with a magnetic,and select aluminum 6061 for processing materials,with soft texture and folds of the phenomenon of post-processing,can shorten processing time of sandblasting,observed in the corresponding magnetic surface roughness of sandblasting processing trends, further study of magnetic properties and processing of sandblasting on the surface。
    first, arrange the preliminary experiment and L18 experiment, to do planning for the processing parameters of the magnetic sandblasting, if magnet placed way (vertical or yaw)and nozzle angle and nozzle distance and the distance of magnetic and magnetic intensity and spray on the processing results (roughness and removal rate and processing range) effects。
    Preliminary experimental results point to a fixed processing time and nozzles angle. Because the angle of the nozzle effect processing area and region, less affected of roughness, processing time is due to be processed 6061 aluminum folds of the phenomenon, and shorten the processing time to observe the processing trends.
    Then by the L18 results the nozzle distance and distance of magnetic as the variable at the same time, magnet processing parameters associated with no significant contribution, therefore fixed the angle of the nozzle and nozzle distance at follow-up single factor experiments。
    The single factor experiments results can be obtained from the magnetic configuration corresponding to the roughness of the trend, the configuration of the jet pressure 5kgf, magnetic intensity 550mT and magnet distance 80mm and when the magnet yaw will be the best performance of the roughness，and get near the magnet end of processing areas will have better performance of the conclusions of the roughness, then used with equation obtained by the regression equation, follow-up can be estimated using the formula in advance of the roughness of the different magnetic configurations, effectively eliminating the number of experiments, and accelerate to find the optimal results。

    目 錄 摘 要................................................................................................................ i Abstract ........................................................................................................... ii~iii 謝 誌.................................................................................................................iv 目 錄..........................................................................................................v~vi 圖 目 錄........................................................................................................vii~ix 表 目 錄............................................................................................................... x 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 研究方法................................................................................................. 2 1-4 論文架構................................................................................................. 5 第二章 文獻回顧................................................................................................. 6 2-1 表面加工相關文獻................................................................................. 6 2-2 田口實驗設計文獻................................................................................. 8 第三章 實驗步驟................................................................................................. 9 3-1 實驗原理................................................................................................. 9 3-1-1 噴砂原理...................................................................................... 9 3-1-2 噴砂設備及材料介紹................................................................ 10 3-1-3 田口實驗設計............................................................................ 12 3-2 實驗與量測設備................................................................................... 15 3-2-1 加工設備&噴射磨料................................................................. 15 3-2-2 量測設備.................................................................................... 16 3-2-3 實驗材料.................................................................................... 18 3-2-4 實驗方法與流程........................................................................ 19 第四章 結果與討論........................................................................................... 21 4-1 磁力噴砂之加工參數測試.................................................................... 21 4-1-1 L18 實驗規劃與步驟.................................................................. 21 4-1-2 前期實驗規劃............................................................................. 22 4-1-3 加工時間對應移除量................................................................. 22 4-1-4 加工時間對應粗糙度................................................................. 23 4-1-5 實驗因子水準設定..................................................................... 23 4-1-6 直交表配置................................................................................. 26 4-1-7 實驗結果分析............................................................................. 26 4-1-8 因子效果回應分析..................................................................... 28 4-1-9 變異數分析(ANOVA)及F 檢定（F-test）............................... 29 4-1-10 品質特性參數組合探討........................................................... 31 4-2 磁力噴砂之單因子實驗........................................................................ 32 4-2-1 單因子實驗規劃......................................................................... 32 4-2-2 實驗數據整理............................................................................ 35 4-2-3 實驗結果分析............................................................................ 36 4-2-3-1 固定磁力強度550mT 的趨勢分析................................ 36 4-2-3-2 固定磁力強度510mT 的趨勢分析................................ 39 4-2-3-3 固定磁力強度470mT 的趨勢分析................................ 42 4-2-3-4 固定噴射壓力5Kgf 的趨勢分析.................................... 45 4-2-3-5 固定噴射壓力4Kgf 的趨勢分析.................................... 48 4-2-3-6 固定噴射壓力3Kgf 的趨勢分析.................................... 51 4-2-3-7 磁力配置的趨勢總結...................................................... 54 4-3 回歸方程式........................................................................................... 55 4-3-1 回歸方程式原理......................................................................... 55 4-3-2 回歸方程式導入......................................................................... 56 4-3-3 回歸方程式總結......................................................................... 61 4-4 磁力牽引............................................................................................... 62 4-4-1 磁力牽引實驗規劃..................................................................... 62 4-4-2 磁力牽引數據整理..................................................................... 63 4-4-3 磁力牽引結果分析..................................................................... 64 4-5 原理說明............................................................................................... 67 第五章 結論....................................................................................................... 69 參考文獻............................................................................................................. 71 作 者 簡 介....................................................................................................... 74 附 錄............................................................................................................. 75 附錄1 鋁材特性參考................................................................................. 75 圖 目 錄 圖3-1 噴砂原理示意圖...................................................................................... 9 圖3-2 噴射方式說明圖........................................................................................ 9 圖3-3 田口參數設計流程................................................................................. 13 圖3-4 磨料噴射加工機...................................................................................... 15 圖3-5 噴射磨料(鋼珠砂)................................................................................... 16 圖3-6 表面粗糙度量測儀................................................................................. 16 圖3-7 電子天平.................................................................................................. 17 圖3-8 超音波洗淨機.......................................................................................... 17 圖3-9 磁通密度計.............................................................................................. 18 圖3-10 實驗流程................................................................................................ 20 圖4-1 加工時間對應移除量趨勢圖................................................................. 22 圖4-2 加工時間對應粗糙度趨勢圖................................................................. 23 圖4-3 實驗擺設示意圖...................................................................................... 24 圖4-4 各實驗物件的功能性說明..................................................................... 24 圖4-5 表面粗糙度量測手法............................................................................. 26 圖4-6 量測位置圖.............................................................................................. 27 圖4-7 因子水準回應圖...................................................................................... 29 圖4-8 噴砂壓力對應粗糙度趨勢圖................................................................. 31 圖4-9 磁鐵直立擺放2D 規劃示意圖............................................................... 32 圖4-10 磁鐵橫擺2D 規劃示意圖..................................................................... 32 圖4-11 5Kgf 550mT 磁鐵距離對應粗糙度Ra 趨勢圖................................... 36 圖4-12 5Kgf 550mT 磁鐵距離對應粗糙度Rz 趨勢圖................................... 37 圖4-13 4Kgf 550mT 磁鐵距離對應粗糙度Ra 趨勢圖................................... 37 圖4-14 4Kgf 550mT 磁鐵距離對應粗糙度Rz 趨勢圖................................... 37 圖4-15 3Kgf 550mT 磁鐵距離對應粗糙度Ra 趨勢圖................................... 38 圖4-16 3Kgf 550mT 磁鐵距離對應粗糙度Rz 趨勢圖................................... 38 圖4-17 5Kgf 510mT 磁鐵距離對應粗糙度Ra 趨勢圖................................... 39 圖4-18 5Kgf 510mT 磁鐵距離對應粗糙度Rz 趨勢圖................................... 39 圖4-19 4Kgf 510mT 磁鐵距離對應粗糙度Ra 趨勢圖................................... 40 圖4-20 4Kgf 510mT 磁鐵距離對應粗糙度Rz 趨勢圖................................... 40 圖4-21 3Kgf 510mT 磁鐵距離對應粗糙度Ra 趨勢圖................................... 40 圖4-22 3Kgf 510mT 磁鐵距離對應粗糙度Rz 趨勢圖................................... 41 圖4-23 5Kgf 470mT 磁鐵距離對應粗糙度Ra 趨勢圖................................... 42 圖4-24 5Kgf 470mT 磁鐵距離對應粗糙度Rz 趨勢圖................................... 42 圖4-25 4Kgf 470mT 磁鐵距離對應粗糙度Ra 趨勢圖................................... 43 圖4-26 4Kgf 470mT 磁鐵距離對應粗糙度Rz 趨勢圖................................... 43 圖4-27 3Kgf 470mT 磁鐵距離對應粗糙度Ra 趨勢圖................................... 44 圖4-28 3Kgf 470mT 磁鐵距離對應粗糙度Rz 趨勢圖................................... 44 圖4-29 5Kgf MD=80mm 磁力強度對應粗糙度Ra 趨勢圖............................ 45 圖4-30 5Kgf MD=80mm 磁力強度對應粗糙度Rz 趨勢圖............................ 45 圖4-31 5Kgf MD=70mm 磁力強度對應粗糙度Ra 趨勢圖............................ 46 圖4-32 5Kgf MD=70mm 磁力強度對應粗糙度Rz 趨勢圖............................ 46 圖4-33 5Kgf MD=60mm 磁力強度對應粗糙度Ra 趨勢圖............................ 47 圖4-34 5Kgf MD=60mm 磁力強度對應粗糙度Rz 趨勢圖............................ 47 圖4-35 4Kgf MD=80mm 磁力強度對應粗糙度Ra 趨勢圖............................ 48 圖4-36 4Kgf MD=80mm 磁力強度對應粗糙度Rz 趨勢圖............................ 48 圖4-37 4Kgf MD=70mm 磁力強度對應粗糙度Ra 趨勢圖............................ 49 圖4-38 4Kgf MD=70mm 磁力強度對應粗糙度Rz 趨勢圖............................ 49 圖4-39 4Kgf MD=60mm 磁力強度對應粗糙度Ra 趨勢圖............................ 50 圖4-40 4Kgf MD=60mm 磁力強度對應粗糙度Rz 趨勢圖............................ 50 圖4-41 3Kgf MD=80mm 磁力強度對應粗糙度Ra 趨勢圖............................ 51 圖4-42 3Kgf MD=80mm 磁力強度對應粗糙度Rz 趨勢圖............................ 51 圖4-43 3Kgf MD=70mm 磁力強度對應粗糙度Ra 趨勢圖............................ 52 圖4-44 3Kgf MD=70mm 磁力強度對應粗糙度Rz 趨勢圖............................ 52 圖4-45 3Kgf MD=60mm 磁力強度對應粗糙度Ra 趨勢圖............................ 53 圖4-46 3Kgf MD=60mm 磁力強度對應粗糙度Rz 趨勢圖............................ 53 圖4-47 磁鐵直立及橫擺個別共27 組的粗糙度結果趨勢圖......................... 54 圖4-48 較佳化比較說明圖.............................................................................. 54 圖4-49 實驗配置參數及表面粗糙度結果帶入Minitab 程式......................... 58 圖4-50 執行Minitab 程式中的回歸方程式..................................................... 58 圖4-51 設定回歸方程式的參數....................................................................... 59 圖4-52 求得回歸方程式的公式....................................................................... 59 圖4-53 回歸方程式的公式準確度................................................................... 60 圖4-54 回歸方程式的公式準確度整理........................................................... 60 圖4-55 磁力牽引效果量測點說明圖............................................................... 62 圖4-56 噴射壓力5kg 磁力牽引效果粗糙度趨勢比較圖............................... 63 圖4-57 噴射壓力4kg 磁力牽引效果粗糙度趨勢比較圖............................... 64 圖4-58 噴射壓力3kg 磁力牽引效果粗糙度趨勢比較圖............................... 64 圖4-59 磁力牽引效果總成比較圖................................................................... 65 圖4-60 加工區域尺寸比較圖........................................................................... 66 圖4-61 加工區域CCD 比較圖......................................................................... 66 圖4-62 磁鐵直擺磁力線分佈圖....................................................................... 67 圖4-63 磁鐵橫擺磁力線分佈圖....................................................................... 68 表 目 錄 表3-1 常用的噴砂機具整理表......................................................................... 10 表3-2 噴砂周邊設備整理表............................................................................. 11 表3-3 噴射磨料整理表...................................................................................... 11 表3-4 鋁材6061 物性表................................................................................... 19 表4-1 實驗設計可控因子及水準值................................................................. 25 表4-2 實驗固定因子與水準值......................................................................... 25 表4-3 實驗結果(L18(21X37 直交表))................................................................ 27 表4-4 表面粗糙度為目標值因子水準回應表................................................. 28 表4-5 表面粗糙度為品質特性之變異數分析及F 檢定................................. 30 表4-6 貢獻度與因子排序關係......................................................................... 30 表4-7 單因子實驗參數規劃圖表..................................................................... 34 表4-8 單因子實驗5Kgf 配置量測數據表....................................................... 35 表4-9 單因子實驗4Kgf 配置量測數據表....................................................... 35 表4-10 單因子實驗3Kgf 配置量測數據表..................................................... 36 表4-11 磁鐵直擺配置及表面粗糙度結果表................................................... 57 表4-12 磁鐵橫擺配置及表面粗糙度結果表................................................... 57 表4-13 交叉比對推估及實際值....................................................................... 61 表4-14 磁力牽引實驗量測數據表................................................................... 63

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