微量切削之刀具與夾具整合設計與分析研究; The Study of an Integrated Tool and Fixture Design for Micro-Volume-Machining Processes

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题名:	微量切削之刀具與夾具整合設計與分析研究;The Study of an Integrated Tool and Fixture Design for Micro-Volume-Machining Processes
作者:	王革創;Ger-chwang Wang
贡献者:	機械工程研究所
关键词:	圓柱方塊相切聯集體;形狀銑刀;特徵點;準線性;多面鑽;彈塑性撓性夾持機構;X-Y-A-B夾具;X-Z-B夾具;一體成型;微量切削系統;切削特徵;N段刃;角度實體模式;geometry characteristic;Micro-motion;X-Z-B fixture;monolithic;X-Y-A-B fixture;Micro-positioning;Elastic-plastic flexure hinge mechanism(EPFHM);PZT;N-segments cutting edges;angle-solid model;Multifacet drills;angle-soli;Rapid prototyping(RP);always normal;characteristic points;computer-aided inspection
日期:	2006-06-23
上传时间:	2009-09-21 11:32:42 (UTC+8)
出版者:	國立中央大學圖書館
摘要:	對於較少污染的切削加工，如免用或使用微小量切削液，可稱為綠色環保切削，而微量切削可達到這目標。根據此種環保趨勢，再由工件幾何特徵及加工精度設計最合適的微量切削之夾具與刀具系統，完成所需切削加工，當可稱此為微量切削系統。要達成前述目的，就必須將該系統分成夾具次系統與刀具次系統。在夾具研究部分，首先以能達加工次微米精度為目標。有關刀具系統部分，必須基於切削特徵進行研究。精密定位夾具延伸應用在微小姿態形成或成形切削，其自由度必須大於3。複合加工如銑拋削，也必須滿足相同需求。為避免組裝間隙的遲滯現象，要求夾具為複雜的一體成型之適服機構(compliant mechanism)，且更容易製造也是必須的。因此，為了精密產生多軸微運動，研究一個由彈塑性撓性平台與壓電致動器結合之彈塑性撓性夾持機構。此系統適當分析後，設備被設計符合撓性機構的作動原理。實驗結果顯示雖然夾具為彈塑性材料，一旦確定滿足所提標準狀況下之設計參數，微運動的產生符合預期，而且勁性是準線性。應用於實際微量銑削可達Ra 0.4的表面粗度。切削刀具新數學模式利用角度實體方塊法找尋設計參數間的關係。刀尖附近切削參數必須定義互為相依關係，以便有類似鑿刃(或是刀尖)幾何的不確定性能被避免。新數學模式在鑿刃及主切刃的效應顯現在本研究中。另外，延伸再發展一新方法以設計形狀銑刀用於銑削精確的複合自由曲面。此研究中，刀斜面、螺旋槽及餘隙刀腹的交點由於在設計及研磨佔有重要地位，必須適當地定義。角度實體方塊分析再被發展以建立形狀刀具實體幾何模型。因此，一個滿足切削特徵的新形狀銑刀能被設計。此外，刀具幾何模型方法被用於以最小量測點的量測策略以驗証正確的刀具幾何圖像。 For a low-pollution required machining process, the Micro-Volume-Machining without cooling liquid is a new trend. Designing an appropriate fixture and tool system based on workpiece geometry characteristics and machining precision is called Micro-volume-machining system. For achieving above objection, the system needs to be devided into fixture subsystem and tool subsystem. Initially, reaching submicrometer is the first goal in the research of fixture design. And, the tool system needs to be studied based on machining characteristics. To perform miniature shape or form machining instead of precise positioning only, the degree of freedom of flexure must be greater than 3. The hybrid machining, such as mill-polishing, must gratify the same requirements either. The need of more intricate functions means not only a more elaborate monolithic and compliant mechanism but more easily made are compulsory. Accordingly, this paper presents an elastic-plastic flexure hinge mechanism (EPFHM) for precisely generating a muliti-axis micro-motion, which is made by elastic-plastic flexure hinge stage (EPFHS) and piezoelectric actuator (PZT). After the appropriate analysis of the system, the device is designed to meet with the prerequisites of flexure hinge mechanism. As long as the certain fulfilled design parameters under the condition of the purposed criteria, the results of experiment reveal that the stiffness is quasi-linear even with the application of elastic-plastic material and the micro-moving is generated in accordance with the anticipated demand. Micro-milling experiment with X-Y-A-B flexure fixture results concealed that the surface roughness is approxing to Ra 0.4 . A new mathematical model for cutting tool is developed using angle-solid-block approach to find the relationship of design parameters. The design parameters around cutter tip need to be defined as dependent relationship one another in order that the uncertainty of chisel edge and main cutting edge determined by existed model can be avoided. The effects of the new mathematical model on the geometry of chisel edge and main cutting edge are shown in this paper. In addition, the extensive study presents a new approach to design a form milling cutter for precisely obtaining the complex free-form surfaces. In this study, the intersection point of rake surface, helix flute and clearance flank is appropriately defined due to its significant role in the design and grinding performance. The angle-solid-block analysis is developed to establish the solid geometry model of new form milling cutter. Hence, a new form milling cutter satisfying the requirements of machining characteristics of workpiece can be designed. In addition, the cutter geometric model can be adopted to map out the measuring strategy with minimum measured points to attain the exact geometric feature of cutter.
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