304不銹鋼之摩擦鑽孔特性研究

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李新民(Shin-Min Lee) 查詢紙本館藏

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機械工程學系

論文名稱

304不銹鋼之摩擦鑽孔特性研究
(Characteristic study on AISI 304 stainless steel using friction drilling)

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摘要(中)

摩擦鑽孔係藉由摩擦生熱的原理加工成形，具有無屑加工及乾式加工的特性。在金屬薄板熱摩擦鑽孔後，可形成3 ~ 4倍工件厚度的軸襯，可以提供後續攻螺紋的內孔，節省焊接螺帽的製程。沃斯田鐵系的不銹鋼材料，具有高韌性、熱傳導係數低及加工硬化等特性，使得一般的傳統麻花鑽頭，對於鑽削這類難加工材料，都會造成刀具的急速磨耗，甚至崩裂，大幅縮短刀具的壽命。但是不銹鋼材料擁有極佳的抗蝕性及抗磨耗性，因此在工業上廣泛的應用並扮演著重要的角色，所以有許多的研究，仍然繼續不銹鋼的鑽孔加工探討，以尋找出最佳的刀具材料、刀具形狀或是加工參數，以改善目前對於不銹鋼材料鑽孔加工的窘境。研究顯示，以進給率100mm/min，轉速1200rpm，比較鍍TiN高速鋼鑽頭、碳化鎢鑽頭與摩擦鑽的磨耗發現，摩擦鑽比其他兩組鑽頭具有更長的刀具壽命。藉由田口實驗法顯示，摩擦鑽錐角度30o，摩擦接觸率50%，進給率100mm/min，轉速3600rpm時，能得到最佳的孔壁表面粗糙度。加工孔橫段面的硬度，以愈接近孔壁邊緣，其硬度值愈高。摩擦鑽的披覆實驗結果顯示，由於固態潤滑效果及熱傳導係數的影響，使得AlCrN披覆層的摩擦鑽頭，測得的鑽頭磨耗及軸向力小於TiAlN披覆與非披覆的摩擦鑽。在不銹鋼摩擦鑽孔加工及其材料強化研究上顯示，微量潤滑鑽頭所加工的材料，要比乾式鑽頭具有更高的硬度產生。

摘要(英)

Friction drilling utilizes the heat generated from the friction between the tool and the workpiece for machining. This process produces no chip, shortens the time required for hole-making and incurs less tool wear, thus lengthening the service life of the drill.After the friction drilling operation had been conducted, a thin plate (workpiece) was formed into a bush with a thickness of 3 times larger than that of the workpiece. The bush can provide a longer area of contact which can fit a shaft firmly. The bush can also be taped to create an internal screw without welding a nut.In this study, tungsten carbide drills with and without coating were employed to make holes in AISI 304 stainless steel, which is known to have high ductility, low thermal conductivity and great hardness.After the optimal drilling parameters of friction drilling were obtained, the optimal geometric shape and friction contact area ratio of the friction drill was selected to conduct experiments and compare with the traditional HSS twist drill coated TiN and Tungsten carbide drill. The results showed that HSS coated TiN was damaged seriously after two drilling runs and Tungsten carbide was already to create a serious wear of drill edge after three runs. However, the friction drill showed little wear and still can normally drill the AISI304 material after 60 runs. Therefore, the friction drill has a better performance than both the HSS coated TiN and the Tungsten carbide drill. Furthermore, the friction drill avoids serious tool wears, enhances drilled hole quality, and prolongs the tool life more significantly. TiAIN and AlCrN were coated onto the drill surface by physical vapor deposition (PVD). Performance of coated and uncoated cutting tools were examined for drillings made under different spindle speeds. Changes in relationship between drill surface temperature, tool wear and axial thrust force during machining were also explored. Experimental results reveal that lubricating effect of the coating and low thermal conductivity of AlCrN caused AlCrN-coated drill to produce the highest surface temperature but the lowest axial thrust force with the least tool wear. However, the difference in performance between coated and uncoated drills diminished with increase in number of holes drilled.

關鍵字(中)

★ 摩擦鑽
★ 摩擦鑽孔
★ 無屑加工
★ 乾式鑽孔
★ 不銹鋼

關鍵字(英)

★ friction drill
★ friction drilling
★ chipless machining
★ dry drilling
★ stainless steel

論文目次

摘要
Abstract
謝誌
目錄
圖目錄
表目錄
第一章緒論..............................................1
1-1 研究動機與目的.......................................................1
1-2 研究背景...........................................2
1-3 文獻回顧...........................................8
1-4 研究方法..........................................15
1-5 本論文之構成......................................17
第二章基本原理.........................................19
2-1 摩擦鑽孔理論......................................19
2-2 田口方法理論......................................22
2-3 材料加工硬化特性..................................25
2-4 表面粗糙度........................................27
2-5 刀具材料性質......................................29
2-6 刀具磨耗機制......................................31
第三章AISI 304不銹鋼的摩擦鑽孔加工特性研究..............34
3-1 前言..............................................34
3-2 實驗說明..........................................36
3-2-1 摩擦鑽製備.....................................38
3-2-2 顯微鏡觀察.....................................40
3-2-3 微硬度量測方法.................................40
3-3結果與討論.........................................42
3-3-1利用田口實驗探討摩擦鑽幾何形狀及鑽削參數........42
3-3-1-1直交表及實驗數據.............................42
3-3-1-2 ANOVA分析...................................45
3-3-1-3 驗證實驗....................................46
3-3-2 不同鑽頭鑽削不銹鋼材料的加工壽命...............47
3-3-3 不銹鋼材料之微硬度探討.........................51
3-4 結論..............................................56
第四章披覆型摩擦鑽的鑽孔特性...........................57
4-1 前言..............................................57
4-2 實驗說明..........................................59
4-3 結果與討論........................................64
4-3-1 溫度的影響.....................................64
4-3-2 摩擦鑽的磨耗...................................66
4-3-3 軸向力與扭力...................................74
4-4 結論..............................................81
第五章不銹鋼摩擦鑽孔加工及其材料強化研究...............82
5-1 前言..............................................82
5-2 實驗說明..........................................84
5-2-1 摩擦鑽製作及鑽孔...............................85
5-2-2 晶相顯微觀察...................................86
5-2-3 硬度試驗.......................................86
5-3 結果與討論........................................88
5-3-1孔壁橫斷面成分分析..............................88
5-3-2晶相顯微組織觀察................................91
5-3-2-1薄板材料上的組織變化.........................91
5-3-2-2凸緣部分的組織變化...........................93
5-3-3微硬度測試......................................99
5-3-3-1乾式摩擦鑽...................................99
5-3-3-1-1自然冷卻..................................99
5-3-3-1-2高壓空氣急速冷卻.........................100
5-3-3-2微量潤滑摩擦鑽..............................101
5-3-3-2-1自然冷卻.................................101
5-3-3-2-2高壓空氣急速冷卻.........................102
5-4 結論.............................................104
第六章摩擦鑽孔對於304不銹鋼與IN-713LC超合金的特性比較.105
6-1 前言.............................................105
6-2 實驗說明.........................................106
6-3 結果與討論.......................................110
6-3-1 孔徑橫斷面之微硬度探討........................110
6-3-2 真圓度探討....................................113
6-3-3 粗糙度探討....................................116
6-4 結論.............................................121
第七章總結論..........................................122
參考文獻...............................................124

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指導教授

顏炳華(Biing - Hwa Yan)

審核日期

2008-10-16

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