不等長微型擠壓絲攻成型加工參數之實驗研究

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黃彥程(Yen-Cheng Huang) 查詢紙本館藏

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機械工程學系

論文名稱

不等長微型擠壓絲攻成型加工參數之實驗研究

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★ M1.2微型擠壓絲攻製程參數之有限元素分析結果

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摘要(中)

本文提出不等長無槽間距 (Unequal Fluteless Spacing, UFS)的概念設計M1.2微型擠壓絲攻。常見的擠壓絲攻具有四個等長的圓弧邊，而UFS擠壓絲攻則具有八個不等長的圓弧邊及四個等長的平直邊。UFS的概念能降低擠壓絲攻的加工扭矩並使其壽命提升，而為了探討其降低扭矩的效應，本文將UFS擠壓絲攻應用於內螺紋的加工實驗。實驗採用的UFS擠壓絲攻和工件材質分別為碳化鎢材質和7075-T651鋁合金。本文考慮的UFS擠壓絲攻加工製程參數(或稱品質因子)有下孔徑及主軸轉速以及潤滑液濃度，採用中央合成設計法規劃並進行實驗，建立攻牙最大扭矩和內螺紋飽牙率的迴歸模型，完成參數最佳化設計的目的。此外，本文亦探討前述加工製程參數對內螺紋成型之扭矩和內螺紋飽牙率的影響。最大扭矩和內螺紋飽牙率迴歸模型，為運用統計軟體Minitab對實驗結果進行統計和變異分析(ANOVA)而建立，且被應用於參數最佳化設計。本文以望小最大扭距為目標函數，內螺紋飽牙率為限制條件進行最佳化設計，以期獲得最佳化的內螺紋飽牙率與最大扭矩。此外，本文依據加工製程參數最佳化的結果進行實驗驗證，結果顯示前述迴歸模型具有良好的預測性。

摘要(英)

This study proposes a conceptual design of M1.2 micro-form taps with Unequal Fluteless Spacing (UFS). The common form tap has four arc edges of equal length, while the UFS form tap has eight arc edges of unequal length and four straight edges of equal. The concept of UFS can reduce the processing torque of the form tap and increase its life. In order to explore the effect of reducing the torque, this study applies the UFS form tap to the processing experiment of internal threads. The UFS form tap and workpiece materials used in the experiment are tungsten carbide and aluminum alloy 7075-T651, respectively. The processing parameters (or control variables) of the UFS form tap considered in this study are the lower aperture, the speed of the rotation and the concentration of the lubrication. The central composite design method is used to plan and conduct experiments to establish the regression model of the maximum torque and the fill rate of the internal thread. The regression model is used to complete the purpose of parameter optimization design. In addition, this study also discusses the influence of the processing parameters on the torque of the internal thread forming and the fill rate of the internal thread. Regression models of maximum torque and the fill rate of the internal thread were established for statistical analysis and analysis of variance (ANOVA) of experimental results using the statistical software Minitab, and were used in the parameter optimization design. In this study, the objective function is to take the desired maximum torque as the objective function, and the fill rate of internal thread is the limiting condition to optimization design, in order to obtain the optimized fill rate of internal thread and maximum torque. In addition, this study conducts experimental verification based on the results of the processing parameters optimization design, and the results show that the regression model of maximum torque and the fill rate of the internal thread have good predictability.

關鍵字(中)

★ 擠壓絲攻
★ 最佳化
★ 中央合成設計
★ 變異數分析

關鍵字(英)

★ form tap
★ optimization design
★ central composite design
★ analysis of variance

論文目次

摘要 i
Abstract ii
誌謝 iv
目錄 v
圖目錄 viii
表目錄 xi
符號說明 xiii
第一章緒論 1
1-1 前言 1
1-2 文獻回顧 2
1-3 研究動機與方法 11
第二章基本理論 14
2-1 擠壓絲攻成型原理 14
2-2 擠壓絲攻設計 16
2-2-1 UFS擠壓絲攻的設計 18
2-2-2 UFS擠壓絲攻的製作方式 28
第三章研究設備與方法 29
3-1 攻牙實驗流程 29
3-1-1 潤滑液的配製 29
3-1-2 攻牙實驗方法 30
3-1-3 加工扭矩的量測 34
3-1-4 內螺紋飽牙率的檢驗 36
3-1-6 軟體介紹 41
3-2 實驗計劃法 45
3-2-1 迴歸分析 46
3-2-2 品質因子和自然水準值 48
3-2-3 曲率效果 49
3-2-5 二階反應曲面法 52
第四章結果與討論 54
4-1 UFS擠壓絲攻成型分析 54
4-2 實驗結果 56
4-2-1 曲率效果的檢驗 56
4-2-2 二階反應曲面法的實驗結果 59
4-3 二階模型的建構與迴歸分析 61
4-3-1 最大扭矩的二階模型迴歸分析及簡化 62
4-3-2 內螺紋飽牙率的二階模型迴歸分析及簡化 65
4-3-3 迴歸模型殘差分析 68
4-4 迴歸模型檢驗 75
4-5 最佳化設計 82
4-6 品質因子對品質特性之效應 83
4-6-1 品質因子對最大扭矩之效應 83
4-6-2 品質因子對內螺紋飽牙率之效應 87
4-7 UFS擠壓絲攻和等長擠壓絲攻之比較 90
第五章結論與建議 92
5-1 結論 92
5-2 建議 93
參考文獻 94
附錄A攻牙實驗之實驗數據 98
附錄B扭矩時間圖與牙型二值圖 101

參考文獻

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指導教授

葉維磬吳明昌(Wei-Ching Yeh Ming-Chang Wu)

審核日期

2022-8-30

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