高深徑比微細孔電化學加工  多重物理量耦合模擬之研究

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姓名

林耆榕(Lin-Chi-Jung) 查詢紙本館藏

畢業系所

機械工程學系

論文名稱

高深徑比微細孔電化學加工多重物理量耦合模擬之研究
(Multi-physics coupling simulation of high aspect ratio micro-hole electrochemical drilling)

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至系統瀏覽論文 (2030-1-20以後開放)

摘要(中)

為節省加工之時間成本，本論文探討使用COMSOL Multiphysics多重物理場耦合軟體應用在預測電化學鑽孔技術之模擬，其中除考慮電場影響外，也加入氣泡對流場的影響。實驗電極採用直徑500 μm之中空黃銅管，加工工件為304不鏽鋼材料，過程中採定電壓加工方式，搭配電解混氣裝置以進行實驗。透過調整不同加工電壓、進給速度、混氣電流，進行12mm淺孔加工實驗。基於淺孔加工結果，加入液體流速之修正係數，進行淺孔模擬線性擬合，並將模擬模型用於預測深孔加工結果，嘗試預測深孔出口之孔徑與極限加工深度，並與實驗結果進行比對，最終完成深徑比為86之深孔加工與一深孔加工模型，未來可透過此模型預測深孔加工出結果，以減少時間成本。
結合實驗與模擬結果顯示，無混氣之深孔加工可加工至深度61mm，混氣電流為0.25A時，加工深度可至95mm，透過淺孔擬合之模型嘗試預測深孔孔徑之誤差隨深度增加而逐漸增加，其中加工深度95mm時，加工孔徑與模擬之誤差為9.4%。

摘要(英)

To reduce the time cost of machining, this study explores the application of COMSOL Multiphysics, a multiphysics coupling software, for simulating the prediction of electrochemical drilling technology. In addition to considering the influence of the electric field, the study also incorporates the effect of bubble convection on the flow field. The experimental electrode used is a hollow brass tube with a diameter of 500 μm, and the workpiece material is 304 stainless steel. The machining process adopts a constant voltage method, combined with an electrolyte gas-mixing device for experimentation. Shallow hole machining experiments with a depth of 12 mm were conducted by adjusting different machining voltages, feed rates, and gas-mixing currents.Based on the shallow hole machining results, a correction coefficient for the liquid flow rate was introduced to perform linear fitting for shallow hole simulations. The simulation model was then applied to predict deep hole machining results, attempting to estimate the bore diameter at the deep hole outlet and the maximum machining depth. These predictions were compared with experimental results, ultimately achieving deep hole machining with an aspect ratio of 86 and developing a deep hole machining model. In the future, this model can be used to predict deep hole machining outcomes and reduce time costs.
The combination of experimental and simulation results indicates that deep hole machining without gas mixing can reach a depth of 61 mm. When the gas-mixing current is 0.25 A, the machining depth can reach 95 mm. The error between the predicted and experimental bore diameters increases with depth; at a machining depth of 95 mm, the error between the experimental and simulated bore diameter is 9.4%.

關鍵字(中)

★ COMSOL Multiphysics
★ 多重物理場耦合
★ 電化學鑽孔
★ 定電壓
★ 修正係數
★ 線性擬合

關鍵字(英)

★ COMSOL Multiphysics
★ multiphysics coupling
★ electrochemical drilling
★ constant voltage
★ correction factor
★ linear fitting

論文目次

摘要 I
Abstract II
目錄 V
圖目錄 VIII
表目錄 XI
第一章緒論 1
1-1 前言 1
1-2 研究動機及目的 2
1-3 文獻回顧 2
1-3-1 電化學鑽孔加工之相關文獻 2
1-3-2 電化學加工模擬相關文獻 5
1-4 論文架構 9
第二章基礎理論 11
2-1 電化學加工 11
2-1-1 電化學鑽孔加工原理 11
2-1-2 法拉第電解定律 12
2-1-3 歐姆定律 13
2-2 電解產氣技術 13
2-2-1 電解產氣基本原理 14
2-2-2 電解產氣流程 15
2-3 混氣電化學加工 15
第三章實驗設備與步驟方法 17
3-1 基礎實驗相關設備 17
3-1-1 深孔電化學加工機 17
3-1-2 電解液循環系統 17
3-1-3 直流電源供應器 19
3-1-4 電解式混合氣體模組 19
3-1-5 線切割放電加工機 20
3-1-6 超音波清洗裝置 21
3-1-7 電流勾表 22
3-1-8 示波器 23
3-1-9 智慧型電導度控制器 24
3-1-10 四極式電導度電極 24
3-2 檢測儀器 25
3-2-1 高精度雷射共軛焦顯微鏡 25
3-2-2 半自動影像測定儀 26
3-3 實驗材料 27
3-3-1 電解液之選用 27
3-3-2 工件材料 28
3-3-3 刀具電極之簡介 30
3-4 實驗方法與實驗流程 31
3-4-1 實驗方法 31
3-4-2 實驗流程 33
第四章多重物理耦合模擬 36
4-1 COMSOL Multiphysics軟體介紹 36
4-2 電化學鑽孔加工模型敘述 36
4-3 電場邊界條件設置 39
4-4 紊流,k-ε模組邊界條件設置 40
4-5 變形幾何模組與多重物理量之邊界條件設置 41
第五章結果與討論 43
5-1 不同混氣電流對實際加工之影響 43
5-2 基於電場影響之模擬結果分析 44
5-2-1 不同電壓下對模擬擴孔量之影響 44
5-2-2 不同進給速度下對模擬擴孔量之影響 46
5-3 基於電場與氣泡流模組耦合影響之模擬結果分析 48
5-3-1 有無修正係數對模擬擴孔量之影響 48
5-4 模擬與實際驗證 53
5-4-1 擴孔量隨深度變化之比較 57
5-4-2 流速隨深度變化之比較 59
第六章結論 63
第七章未來展望 64
參考文獻 65

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指導教授

洪榮洲

審核日期

2025-1-20

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