| 摘要: | 針對當今積層製造零組件於國防、航太及醫療產業的大量應用，本研究提出一機械手臂輔助電解複合研磨拋光製程技術。此加工方法整合多軸機械手臂與電解研磨拋光技術，可有效且快速地降低積層製造鈦合金材料的表面粗糙度。研究內容包含系統機構規劃、夾治具設計、電極型式選用、拋光路徑規劃及電解複合研磨拋光參數的研究，並分析各加工參數因應複雜曲面形態下之積層製造鈦合金工件的拋光改善效果。根據拋光後的工件表面粗糙度數據及表面微觀結構觀察進行工序判斷，為建立高效的拋光系統提供參考依據。
本論文依據工件形貌特徵設計對應拋光電極毛刷、電解液供應模式及拋光路徑設計，經由機械手臂夾持電極毛刷，針對複雜曲面之葉片工件表面進行拋光修整，並透過實驗分析探討拋光路徑模式及各種加工參數如加工電流、電極移動速度、電極轉速、拋光次數對積層製造鈦合金葉片粗糙度、粗糙度均勻度、工件幾何輪廓，以及顯微結構的影響。實驗結果顯示在維持葉片幾何輪廓下，本研究開發之系統能夠有效降低工件表面粗糙度得到高精度且高品質之均勻表面，葉片工件平均表面粗糙度由Ra 25 µm降低至Ra 0.603 µm、表面粗糙度均勻度85.12 %。另外，透過TEM進行工件表層微觀結構觀測、XPS進行工件表面化學成份分析，發現經本研究開發之研磨系統進行電解複合研磨拋光後，工件表面在電化學作用下會形成一層結構更緻密的鈍化膜，增加葉片工件材料之耐腐蝕性。
;In response to the extensive application of additive manufacturing components in defense, aerospace, and medical industries, this study proposes a robotic electrochemical mechanical polishing method. This method combines a multi-axis robotic arm with electrochemical mechanical polishing process, that could effectively and significantly reduce the surface roughness of additively manufactured titanium-based materials. The research includes system mechanism design, fixture design, electrode selection, polishing path planning, and the study of polishing parameters. Process evaluation is conducted based on surface roughness data and microstructure observations of the polished workpieces, providing a reference for establishing an efficient polishing system.
This study designs polishing electrode brushes, electrolyte supply modes, and polishing paths corresponding to the morphological characteristics of the blade workpiece. Surface polishing and refinement are performed on the complex curved surfaces of blade workpieces by controlling electrode brush with a robotic arm. Experimental analyses are discussed in detail to explore the influence of polishing path patterns and various processing parameters, such as machining current, electrode moving speed, electrode rotation speed, and polishing repetitions, on the machining characteristics of additively manufactured titanium alloy blades. Experimental results show that the developed system effectively reduces surface roughness while maintaining the geometric profile of blade workpieces. The average surface roughness of the blade workpieces decreased from Ra 25 µm to Ra 0.603 µm, with a surface roughness uniformity of 85.12%. Additionally, TEM observations of the microstructure on the workpiece surface and XPS analysis of the chemical composition of the workpiece surface revealed that, after electrochemical mechanical polishing with the developed system, a denser passivation film was formed on the workpiece surface due to the electrochemical action. This enhances the corrosion resistance of the blade material. |
