博碩士論文 88343008 詳細資訊



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姓名 蔡憲忠(Shien-Chung Tsai)  查詢紙本館藏   畢業系所 機械工程學系
論文名稱 銅鉻電極及尿素加工液對放電加工表面改質效果之研究
(Surface Modification Effects by Electrical Discharge Machining with Cu-Cr Electrode and Urea Dielectric)
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摘要(中) 摘 要
放電加工表面因在加工液中受到急熱急冷作用容易產生微裂紋、氣孔、殘留應力等缺陷，這些缺陷不僅會造成加工表面精度不佳，更是造成機件使用壽命縮短的主因。因此如何維持加工效率的同時又能對放電加工表面進行改質強化，以提升加工表面之耐磨、耐蝕能力，是本文主要探討的主題。
經由本研究的實驗結果分析顯示，新開發的簡易複合電極以Cu-20wt%Cr的混合比例及在20MPa的壓力下所製作的電極具有最佳的材料去除率，而且實驗結果亦顯示在本實驗條件範圍內，此複合電極比傳統熔煉Cu電極具有更高的材料去除率，且其工件表面的微裂紋較少，再鑄層亦較薄，同時也發現複合電極之Cr成分會轉移到工件表面，增進表面耐蝕性能。而使用蒸餾水中添加尿素作為加工液對純鈦金屬之實驗，由於放電加工時產生高溫使尿素中解離出氮(N)元素並與工件材料(純鈦)產生化學作用，形成氮化鈦(TiN)的陶瓷表面硬化層；同時經由耐磨耗測試後發現，加工液中添加適量尿素可提升加工表面的耐磨耗能力、降低表面摩擦力，達到表面改質強化的效果。而在尿素加工液中添加鈦粉末進行放電加工時，由於添加粉末而造成極間間隙增大、促進放電分散的效應，使得加工屑容易排除，也因此促進放電穩定的進行，所以可提高材料的去除率、降低表面的粗糙度，同時尿素加工液中添加鈦粉末進行放電加工，會經由加工過程中放電柱的離子化作用解離出氮(N)元素並轉移至加工表面而形成表面改質層，將可提升加工表面的機械性質。
摘要(英) Abstract
The Electrical discharge machining (EDM) surfaces have the defects of microcracks, pores and residual stresses formed by the strong temperature gradient during machining. These defects result not only in poor surface precision, but also in a shortened service life of machinery parts. Thus, the machined surface modification and machining efficiency need to be considered simultaneously for EDM applications, and they are also the interesting topics in this investigation.
From the experimental results show that Cu-Cr composite electrodes with a Cu-20wt.%Cr mixing ratio and a 20 MPa sintering pressure obtained an excellent MRR. Moreover, this work also reveals that the composite electrodes obtained a higher MRR than Cu metal electrodes; the recast layer was thinner, and fewer cracks were present on the machined surface. Furthermore, the Cr contained in the composite electrode migrated to the work piece, resulting in good corrosion resistance of the machined surface after EDM. Moreover, workpiece surface modification by adding urea into the dielectric used in machining pure titanium metal. Experimental results indicate that the nitrogen element decomposed from the dielectric that contained urea, migrated to the work piece, forming a TiN hard layer, resulting in good wear resistance and exhibited improved friction of the machined surface after EDM. In addition, added conductive particle into urea solution could widen the discharge gap to facilitate the expelling of debris and divide the discharge energy to reduce the surface roughness. Moreover, the added powder could be transferred and penetrated to the machined surface by ionization of the discharge channels. Therefore, the machined surface achieves the modification and reinforcement.
關鍵字(中) ★ 放電加工
★ 複合電極
★ 表面改質
★ 尿素		 關鍵字(英) ★ Electrical discharge machining
★ composite electrode
★ surface modification
★ urea
論文目次 目 錄
中文摘要 I
英文摘要 II
謝誌 III
目錄 IV
圖目錄 VII
表目錄 IX
第一章 緒論1
1-1 研究動機與目的 1
1-2 研究的背景 2
1-3 文獻回顧 5
1-4 研究方法 12
1-5 本論文之構成 13
1-6 參考文獻 15
第二章 Cu-Cr複合電極之放電加工表面改質效果研究 24
2-1 前言 24
2-2 實驗方法 25
2-3 結果與討論 28
2-3-1 Cu-Cr複合電極製作條件對放電加工特性之影響 28
2-3-1-1 Cu-Cr粉末混合比例對材料去除率及電極消耗率之影響 28
2-3-1-2 Cu-Cr混合粉末燒結壓力對材料去除率及電極消耗率之影響 30
2-3-1-3 引弧電壓對材料去除率及電極消耗率之影響 32
2-3-1-4 不同加工極性對表面粗糙度的影響 34
2-3-1-5 最佳Cu-Cr複合電極之製作條件及加工電氣條件 38
2-3-2 Cu-Cr複合電極對放電加工特性的影響 39
2-3-2-1 Cu-Cr複合電極對材料去除率的影響 39
2-3-2-2 Cu-Cr複合電極對電極消耗率的影響 39
2-3-2-3 Cu-Cr複合電極對表面粗糙度的影響 41
2-3-3 Cu-Cr複合電極與熔煉Cu電極對放電加工特性的影響 43
2-3-4 銅鉻複合電極對表面改質的效果 45
2-3-4-1 加工表面元素分析 45
2-3-4-2加工表面微硬度分佈 47
2-3-4-3加工表面耐蝕性能 47
2-4 結論 50
2-5 參考文獻 51
第三章 尿素加工液對純鈦金屬放電加工之表面改質效果研究 53
3-1 前言 53
3-2 實驗內容與方法 54
3-3 結果與討論 57
3-3-1 不同加工液對放電加工特性的影響 57
3-3-2 尿素加工液對材料去除率的影響 57
3-3-3 尿素加工液對電極消耗率的影響 57
3-3-4 尿素加工液對表面粗糙度的影響 61
3-3-5 尿素加工液對表面改質的效果 63
3-3-5-1 加工表面成分分析 63
3-3-5-2 加工表面耐磨耗性能分析 64
3-3-5-3 加工表面微硬度分佈 68
3-4 結論 70
3-5 參考文獻 71
第四章 尿素加工液中添加鈦粉末對改善放電加工特性之研究 73
4-1前言 73
4-2 實驗方法 74
4-2-1實驗設備與方法 74
4-2-2實驗材料 74
4-3 結果與討論 77
4-3-1 尿素加工液中添加粉末對材料去除率的影響 77
4-3-2 尿素加工液中添加粉末對電極消耗率的影響 77
4-3-3 尿素加工液中添加粉末對表面粗糙度的影響 81
4-3-4 極性的影響 84
4-3-5 加工表面元素分析 87
4-3-6 加工表面接觸角的分析 89
4-4 結論 92
4-5 參考文獻 93
第五章 總結論 96
參考文獻 第一章
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第二章
1. N. Mohri, N. Saito, Y. Tsunekawa, Metal surface modification by electrical discharge machining with composite electrode, Annals of the CIRP 42 (1993) 219–222.
2. A. Gangadhar, M.S. Shunmugam, P.K. Philip, Surface modification in electrodischarge processing with a powder compact tool electrode, Wear 143 (1991) 45–55.
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9. Y. Fukuzawa, Y. Kojima, T. Tani, E. Sekiguti, N. Mohri, Fabrication of surface modification layer on stainless steel by electrical discharge machining, Materials and Manufacture Processes 10 (2) (1995) 195–203.
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12. L.C. Lee, L.C Lim, Y.S. Wong, Crack susceptibility of electrodischarge machined surfaces, Journal of Materials Processing Technology 29 (1992) 213–221.
13. Q.Y. Ming, L.Y. He, Powder-suspension dielectric fluid for EDM, Journal of Materials Processing Technology 52 (1995) 44–54.
14. B.H. Yan, Y.C. Lin, F.Y. Huang, C.H. Wang, Surface modification of SKD 61 during EDM with metal powder in the dielectric, Materials Transactions 42 (12) (2001) 2597–2604.
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第三章
1. K.E. Budinski, Tribological properties of titanium alloys, Wear 151 (1991) 203-217.
2. M.S. Shunmugam, P. K. Philip, Improvement of Wear Resistance by EDM with Tungsten Carbide P/M Electrode, Wear 171 (1994) 1-5.
3. N. Mohri, N. Saito, Y. Tsunekawa, Metal Surface Modification by Electrical Discharge Machining with Composite Electrode, Annals of the CIRP 42 (1993) 219-222.
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5. K. Furutani, A. Saneto, H. Takezawa, N. Mohri, H. Miyake, Accretion of titanium carbide by electrical discharge machining with powder suspended in working fluid Precision Engineering, Journal of the International Societies for Precision Engineering and Nanotechnology 25 (2001) 138–144.
6. B.H. Yan Y.C. Lin, F.Y. Huan C.H. Wang, Surface modification of SKD 61 during EDM with Metal powder in the dielectric, Materials Transactions, JIM 42 (12) (2001) 2597-2604.
7. S.L. Chen, B.H. Yan, F.Y. Huang, Influence of kerosene and distilled water as dielectrics on the electric discharge machining characteristics of Ti-6Al-4V, Journal of Materials Processes Technology 87 (1999) 107-111.
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11. M.R. Patel, M.A. Barrufet, P.T. Eubank, D.D. DiBitonto, Theoretical models of the electrical discharge machining process. II. The anode erosion model, Journal of Applied Physics 66 (9) (1989) 4101-4111.
12. M. Toren, Y. Zvirin, Y. Winograd, Melting and evaporation phenomena during electrical erosion, Journal of Heat Transfer (1989) 576-581.
13. Y. Tsuekawa, M. Okumiya, N. Mohri, E. Kuribe, Formation of composite layer containing TiC precipitates by electrical discharge alloying, Materials Transactions, Japan Institute of Metals 38(7) (1997) 630-635.
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16. D.I. Pantelis, N.M. Vaxevanidis, A.E. Houndri, P. Dumas, M. Jeandin, Investigation into the application of electrodischarge machining as steel surface modification technique, Surface Engineering 14 (1) (1998) 55–61.
第四章
1. M.L. Jeswani, Effect of the addition of graphite powder to kerosene used as the dielectric fluid in electrical discharge, Wear 70 (1981) 133-139.
2. H. Narumiya, N. Mohri, N. Saito, H. Ohtake, Y. Tsunekawa, T. Takawashi, K. Kobayashi, EDM by powder suspended working fluid, Proceedings of International symposium for Electro-Machining, The Japan Society of Electrical-Machining Engineers (1989) 5-8.
3. B.H. Yan, S.L. Chen, Effect of dielectric with suspended aluminum powder on EDM, Journal Chinese Society of Mechanical Engineers (1993) 307-312.
4. Q.Y. Ming, L.Y. He, Powder-suspension dielectric Fluid for EDM, Journal of Materials Processing Technology 52 (1995) 44-54.
5. Y.F. Tzeng, C.Y. Lee, Effect of powder characteristics on electrodischarge machining, International Journal of Advanced Manufacturing Technology 7 (2001) 586-592.
6. W.S. Zhao, Q.G. Meng, Z.L. Wang, The application of research on powder mixed EDM in rough machining, Journal of Materials Processing Technology 129 (2002) 30-33.
7. F. Klocke, D. Lung, G. Antonoglou, D. Thomaidis, The effects of powder suspended dielectrics on the thermal influenced zone by electrodischarge machining with small discharge energies, Journal of Materials Processing Technology 149 (2004) 191–197.
8. B.H. Yan and S.L. Chen, Characteristics of SKD11 by complex process of electrical discharge machining using liquid suspended with aluminum powder, Journal Japan Inst. Metals 58 (9) (1994) 1067-1072.
9. Y.S. Wong, L.C. Lim, W.M. Tee, Near-mirror-finish phenomenon in EDM using powder-mixed, Journal of Materials Processing Technology 79 (1998) 30-40.
10. P. Pecas, E. Henriques, Influence of silicon powder-mixed dielectric on conventional electrical discharge machining, International Journal of Machine Tools & Manufacture 43 (2003) 1465–1471.
11. B.H. Yan Y.C. Lin, F.Y. Huan C.H. Wang, Surface modification of SKD 61 during EDM with Metal powder in the dielectric, Materials Transactions, JIM 42 (12) (2001) 2597-2604.
12. K. Furutani, A. Saneto, H. Takezawa, N. Mohri, H. Miyake, Accretion of titanium carbide by electrical discharge machining with powder suspended in working fluid Precision Engineering, Journal of the International Societies for Precision Engineering and Nanotechnology 25 (2001) 138–144.
13. D.D. DiBitonto, P.T. Eubank, M.A. Barrufet, Theoretical models of the electrical discharge machining process. I. A simple cathode erosion model, Journal of Applied Physics 66 (9) (1989) 4095-4103.
14. M.R. Patel, M.A. Barrufet, P.T. Eubank, D.D. DiBitonto, Theoretical models of the electrical discharge machining process. II. The anode erosion model, Journal of Applied Physics 66 (9) (1989) 4101-4111.
15. M. Toren, Y. Zvirin, Y. Winograd, Melting and evaporation phenomena during electrical erosion, Journal of Heat Transfer (1989) 576-581.
16. L.C. Lee, L.C. Lim, Y.S. Wong, Crack susceptibility of electro-discharge machined surfaces, Journal of Materials Processing Technology 29 (1992) 213-221.
17. H.T. Lee, T.Y. Tai, Relationship between EDM parameters and surface crack formation, Journal of Materials Processing Technology 142 (2003) 676–683.
18. Y. Tsuekawa, M. Okumiya, N. Mohri, E. Kuribe, Formation of composite layer containing TiC precipitates by electrical discharge alloying, Materials Transactions, JIM 38 (7) (1997) 630-635.
19. R.J. Good, Adsorption at interfaces, in: K.L. Mittal (Ed.), ACS Symposium Series No. 8, American Chemical Society, Washington, DC, (1975).
20. L. Ponsonnet, K. Reybier, N. Jaffrezic, V. Comte, C. Lagneau, M. Lissac, C. Martelet, Relationship between surface properties (roughness, wettability) of titanium and titanium alloys and cell behaviour, Materials Science and Engineering C 23 (2003) 551–560.
21. E. Lugscheider, K. Bobzin, The influence on surface free energy of PVD-coatings, Surface and Coatings Technology 142-144 (2001) 755-760.
指導教授 顏炳華(Biing-Hwa Yan) 審核日期 2005-1-23
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