| 摘要: | 本次論文研究，可分為兩部份，分別以銅材料，做為製造高深寬比微流道成品材料。另外使用銅、鋁6061材料，做為製造微結構成品材料。搭配使用電腦數控銑床(Computer numerical control milling machine , CNC milling machine)進行微銑削(Micro-milling)，利用電腦數控銑床優勢，例如:微流道模具快速建模、高深寬比微流道、良好微流道尺寸控制和即時進行少量化生產等優勢，微觀銑削製程時與宏觀微銑削製程，有著不同銑削狀態，被稱為尺寸效應(Size effect)，本次研究製造，著重在高深寬比微流道，然而使用加長型端銑刀(Extra long end-mill)、加長型球形端銑刀(Extra long ball-end-mill)進行銑削時，因為參數設定不同，例如：主軸轉速(Spindle speed,N)、進給速率(Feed rate,V_f)、每刀切深量(Axial cutting depth,a_P)、每齒進給率(Feed per tooth,f_z)，皆具有不同犁切效應(Ploughing effect)影響，對於微銑削後，表面粗糙度(Surface roughness,R_z)、毛邊尺寸(Burr size)，具有不同影響成品精準度，且使用其他方式，並不容易移除毛邊，故將對於加長型端銑刀，使用銑削參數進行研究。此外，使用加長型球形端銑刀具，產生自然扇形高度(Scallop height)，影響微銑削後表面粗糙度，且搭配十字型刀具銑削路徑，在材料表面製造出金字塔微結構(Microstructure)，並研究此金字塔微結構尺寸變化。;The present research can be divided into two parts, each focusing on the utilization of copper materials for the fabrication of high aspect ratio microchannels as well as the use of copper and aluminum 6061 materials for the production of microstructures. Micro-milling processes are conducted using a computer numerical control milling machine (CNC milling machine). Leveraging the advantages of CNC milling machines, such as rapid modeling of microchannel molds, the creation of high aspect ratio microchannels, precise control of microchannel dimensions, and real-time small-scale production capabilities, the micro-milling process exhibits distinct milling conditions when compared to macro-milling processes. This phenomenon is known as the size effect. In this study, the emphasis is placed on high aspect ratio microchannels.
However, when utilizing extended end mills and extended ball-end mills for milling, variations in milling parameters, such as spindle speed(N), feed rate(V_f), axial cutting depth per pass (a_P), and feed per tooth (f_z) result in different ploughing effects. Consequently, after micro-milling, the surface roughness (R_z) and burr size exhibit differing impacts on the precision of the final product. Additionally, alternative methods are not easily effective in removing burrs. Therefore, this research investigates the use of extended end mills with different milling parameters.
Furthermore, the use of extended ball-end mills produces a natural scallop height, which affects the surface roughness after micro-milling. When combined with a cross-shaped toolpath, it creates pyramid microstructures on the material′s surface. The variation in the dimensions of these pyramid microstructures is also studied. |
