軸向超音波振動輔助於放電加工SKD11微孔之研究;A Study on Axial Ultrasonic Vibration-Assisted Electrical Discharge Machining of Micro Holes in SKD11

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題名:	軸向超音波振動輔助於放電加工SKD11微孔之研究;A Study on Axial Ultrasonic Vibration-Assisted Electrical Discharge Machining of Micro Holes in SKD11
作者:	陳正宗;CHEN, ZHENG-ZONG
貢獻者:	機械工程學系在職專班
關鍵詞:	超音波振動輔助;放電加工;模具鋼;微孔;ultrasonic vibration assistance;Electrical discharge machining;Tool steel;Micro hole
日期:	2026-01-15
上傳時間:	2026-03-06 19:04:00 (UTC+8)
出版者:	國立中央大學
摘要:	本研究針對熱處理後高硬度SKD11模具鋼進行放電加工，熱處理後之SKD11模具鋼具備高硬度、高強度與優異耐磨性，然而在傳統切削或研磨加工製程中，經常遭遇刀具損耗嚴重與加工效率低下的問題。放電加工(EDM)製程因不受材料硬度影響，廣泛應用於難加工材料領域。本研究進一步導入軸向超音波振動工具電極進行SKD11微孔加工之研究，採用加工參數包括超音波功率段數、脈衝休止時間、高壓電流與低壓電流，並針對加工參數對品質特性之影響進行分析，品質特性包括加工時間、微孔深度、微孔孔徑、電極損耗量與微孔側壁之表面粗糙度，並輔以掃描式電子顯微鏡(SEM)與雷射共軛焦暨白光干涉顯微鏡(LSCM)觀察微孔表面形貌。實驗結果顯示，透過軸向超音波振動輔助，能有效促進介電液循環與放電渣排除，降低加工時集中放電現象，從而增進加工效率與改善工件加工後之微孔內表面粗糙度。此外，加工參數中之高壓電流與低壓電流對加工時間、微孔孔深有顯著影響，而脈衝休止時間則對微孔內表面粗糙度亦具顯著影響。當採用本研究較佳實驗參數組合為超音波功率等級8、高壓電流2.4 A、脈衝休止時間 13 μs及低壓電流1 A時，可獲得2.14 μmRa之加工後表面粗糙度，相較於無超音波振動輔助加工時之表面粗糙度2.53 μmRa下降了15.42%，加工時間由2170秒降低至1532秒，加工效率提升了29.36%，能夠有效兼顧表面品質與加工效率。 ;This study conducted electrical discharge machining on high-hardness SKD11 mold steel. Heat-treated SKD11 mold steel is characterized by high rigidity, high strength and excellent resistance to abrasion. However, in traditional machining or grinding process, there often exist problems of serious abrasion of cutting tools and low machining efficiency. electrical discharge machining process is widely used in fields where it is difficult to machine materials because this process is not affected by rigidity of materials. This research further introduces tool electrode with axial ultrasonic vibration to study machining of SKD11 micro holes. Machining parameters adopted contain ultrasonic power level, high voltage current, pulse off time, and low voltage current. The influence of machining parameters on quality characteristic is analyzed. Quality characteristic include machining time, micro hole depth, micro hole diameter, electrode wear quantity and micro hole surface roughness. Scanning electron microscope and laser scanning confocal microscopy are adopted to observe surface appearance of micro holes. Results of experiments show that Axial Ultrasonic Vibration can effectively promote circulation of dielectric fluid and removal of discharge slag and reduce phenomenon of centralized electricity discharge during machining so as to enhance machining efficiency and micro hole surface roughness in machined workpieces. In addition, among machining parameters, high voltage current and low voltage current have outstanding effect on machining time and depth of micro holes, while pulse off time also has obvious influence on micro hole surface roughness of micro holes. Optimal experiment parameter composition of this research is ultrasonic power level 8 ,high voltage current 2.4 A, pulse off time 13 μs and low voltage current 1 A . When this composition is adopted, surface roughness after machining can reach 2.14 μmRa. Comparing with micro hole surface roughness 2.53 μmRa obtained in machining without assistance of ultrasonic vibration, micro hole surface roughness is reduced by 15.42%, machining time is decreased from 2170 seconds to 1532 seconds and machining efficiency is improved by 29.36%. This method can effectively ensure both surface quality and machining efficiency.
顯示於類別:	[機械工程學系碩士在職專班 ] 博碩士論文

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