常用金屬材料在硝酸鈉與氯化鈉電解液中電化學加工特性之探討

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趙冠瑋(Guan-Wei Chao) 查詢紙本館藏

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機械工程學系

論文名稱

常用金屬材料在硝酸鈉與氯化鈉電解液中電化學加工特性之探討
(The Investigation of Electrochemical Machining Characteristics for Common Metallic Materials in NaNO3 and NaCl Electrolytes)

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摘要(中)

電化學加工是屬於非傳統加工的一種，利用低電壓、高電流使材料以離子狀態快速溶解，而達到加工目的的加工方法，其優點為設備成本低廉、刀具不易損壞、工件表面不含殘留應力等，且複雜的工件也能輕易地加工。在過去文獻當中，對於材料的電化學特性資訊較不足，因此本文旨在建立常用金屬材料的電化學特性資料庫，以供未來業界做參考。

本實驗分成三個部分：（一）利用恆電位儀量測電流-電壓曲線圖（I-V Curve），探討材料的電化學特性。（二）靜態電化學加工量測，利用電解液側向流場，通電5分鐘，紀錄電流、移除量並計算出電流密度。（三）加工後工件表面量測，包括工件表面結構狀況以及表面元素。並建立常用金屬電化學特性資料庫。探討的金屬工件包括不鏽鋼、模具鋼、高速鋼、構造用合金鋼、鈦合金、鎳合金、哈氏合金、磷青銅以及碳化鎢等等。本研究採用兩種中性的電解液硝酸鈉（NaNO3）與氯化鈉（NaCl）進行電化學加工。

由實驗結果顯示，在氯化鈉電解液中加工，電流密度比在硝酸鈉電解液中高，陽極工件移除量也較多，但是表面精度與粗糙度方面，利用氯化鈉電解液加工卻比較差。含鎢或銅的材料，因材料硬度較硬且表面易有鈍化層生，碳鋼類的材料在氯化鈉電解液中易有黑層（黑色鬆散的粒子層），皆會阻礙加工。鈦金屬材料在中性電解液中，加工品質均不佳，加工過程會有雜質稀出而造成金屬表面有許多孔洞。

摘要(英)

Electrochemical machining (ECM) is one of the non-traditional manufacturing process which works on the low voltage and high current to dissolve materials rapidly in ion states. It has advantages such as inexpensive machining equipment, little or no tool wear, no residual stress on the work piece surface, and competence for machining complex geometries. In previous studies, it had not enough information about electrochemical characteristics of materials, so the aim of thesis is to establish the electrochemical characteristics for common metallic materials. It can be used as reference for industry in the future.

This article can be divided into three parts, namely, (1) Using autolab to measure current-voltage curves (I-V curves), and investigated electrochemical characteristics of materials. (2) Static electrochemical machining measurement: discharged for 5 minutes and recorded the current, material removal amounts and calculated the corresponding current density. The electrolyte flows into the machining area in the side direction. (3) After machining the work piece surface condition was measured, including surface structure and elements contained. The electrochemical characteristics and machining work database were established. Different kind of materials were performed, including stainless steels, pattern die steels, high speed steels, chromium molybdenum steels, titanium alloy, nickel alloy, Hastelloy alloy, phosphor bronze, and tungsten carbide alloy. They were manufactured in NaNO3 and NaCl electrolytes.

Experimental results show that, most of the materials in the NaCl electrolyte, the current density and material removal amount are larger than that in the NaNO3 electrolyte. However, the surface precision and roughness are poor in NaCl electrolyte. The materials contained copper or tungsten are high hardness and the passivation layer will be formed on the surface. The black film, also formed on the surface in NaCl electrolyte and materials contained carbon steels, will cause machining difficult. The materials contained titanium have poor machining quality in the neutral electrolytes, where the particles will be dissolved during the machining process and result in pitting phenomenon on the work piece surface.

關鍵字(中)

★ 電化學加工
★ 電化學特性
★ 電流密度
★ 移除量

關鍵字(英)

★ Electrochemical machining
★ Electrochemical characteristic
★ Current density
★ Material removal amounts

論文目次

摘要 I
Abstract III
誌謝 V
目錄 VI
圖目錄 XI
表目錄 XVI
符號說明 XVII
第一章緒論 1
1-1前言 1
1-2電化學加工 3
1-3文獻回顧 4
1-3-1電化學加工 5
1-3-2常用金屬材料之電化學加工 8
1-4研究背景與目的 12
第二章基礎理論 14
2-1電化學加工基本理論 14
2-1-1電流密度（Current Density） 16
2-1-2電流效率（Current Efficiency） 16
2-1-3歐姆定律（Ohm’s Law） 17
2-1-4極化（Polarization） 17
2-2電解液導電度 20
2-2-1電解液 20
2-2-2電解液導電度（Conductivity） 20
2-2-3導電度與濃度之關係 21
2-3線性掃描伏安法 22
2-4電化學拋光 22
第三章實驗設備與步驟 25
3-1實驗設備 25
3-1-1恆電位儀 25
3-1-2直流電源供應器 26
3-1-3導電度量測儀 26
3-1-4秤重計 27
3-1-5幫浦 27
3-1-6磁石攪拌器 27
3-1-7低真空掃描式電子顯微鏡 28
3-1-8能量散射光譜儀 28
3-1-9金相顯微鏡 29
3-1-10 X光粉末繞射儀（X-Ray Diffraction, XRD） 29
3-2實驗材料 30
3-2-1電解槽 30
3-2-2電極材料 30
3-2-3電解液 32
3-3實驗步驟與方法 32
3-3-1材料電化學特性 33
3-3-2靜態電化學加工 34
3-3-3工件表面狀況量測 35
3-4實驗注意事項 35
第四章實驗結果與討論 37
4-1 Inconel718加工特性 39
4-2鈦金屬加工特性 41
4-3銅鎢合金加工特性 43
4-4磷青銅加工特性 45
4-5不鏽鋼加工特性 46
4-6哈氏合金（C276）加工特性 49
4-7碳化鎢加工特性 50
4-8模具鋼加工特性 52
4-9構造用合金鋼加工特性 54
4-10高速鋼加工特性 55
第五章結論與未來展望 57
5-1結論 57
5-2未來展望 59
參考文獻 60
附圖 66
附表 129

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指導教授

洪勵吾(Lih-Wu Hourng)

審核日期

2016-7-6

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