行星式機構結合二維振動輔助磁力研磨應用於SUS304不鏽鋼曲面凹槽之研究

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姓名

廖振淵(Chen-yuan Liao) 查詢紙本館藏

畢業系所

機械工程學系在職專班

論文名稱

行星式機構結合二維振動輔助磁力研磨應用於SUS304不鏽鋼曲面凹槽之研究
(A Study of Magnetic Polishing for SUS304 Curve Surface with Planetary Bodies Combined Two-Dimensional Vibration)

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摘要(中)

摘要
傳統的振動輔助方式，多為平行或垂直於工件表面的單軸向往復振動機制，垂直工件表面的振動輔助機制易造成研磨刮痕加深且不易得到鏡面效果，而平行工件表面易在同一表面出現重複研磨痕跡，造成表面研磨不均。
本研究是以驗證自行開發的行星機構結合二維振動輔助磁力研磨機制於不鏽鋼曲面凹槽上進行拋光，其主要目的是利用行星機構自轉與公轉的優點，使其表面形成高密度的交叉紋路外，還可達到省時節能又環保，進而達到高品質、高效率、低耗能的指標。
藉由控制磁極間距、振動平台振幅、鋼砂粒徑、SiC、重量、鋼砂重量、研磨液重量、振動平台頻率、磁極轉速…等一系列的實驗探討後，得知行星機構結合二維振動輔助機制能有效提昇表面品質與效率。
經由田口驗證實驗可以得知，對於平面表面粗糙度Ra 0.058μm的改善較佳參數組合為：磁極間距1mm、振動平台振幅0.1mm、鋼砂粒徑0.125mm、SiC重量3g、鋼砂重量0.5g*2、研磨液重量5g、振動平台頻率16.667Hz、磁極轉速(伺服轉速)500rpm(公轉156)。
對於曲面凹槽粗糙度Ra 0.058μm的改善較佳參數組合為：磁極間距0.5mm、振動平台振幅0.1mm、鋼砂粒徑0.125mm、SiC重量3g、鋼砂重量0.5g*2、研磨液重量5g、振動平台頻率16.667Hz、磁極轉速500rpm(公轉156)。
行星機構結合二維振動輔助磁力研磨加工法在較佳參數組合下，能有效改善平面不鏽鋼表面粗糙度由Ra 0.23μm改善至0.058μm，改善率達到74%；及改善曲面凹槽不鏽鋼表面粗糙度由Ra 0.22μm改善至0.058μm，改善率達到74%。由此可以證明行星機構結合二維振動輔助機制是能夠有效提升平面與凹槽表面的表面品質的。
關鍵字：行星機構、二維振動、不鏽鋼拋光、自轉與公轉

摘要(英)

Abstract
The normal vibration directions of vibration-assisted magnetic abrasive finishing are all parallel or perpendicular to the surface of workpiece. It’s shortcomings are easily lead to more scratches on the surface, and difficult to obtain mirror effect.
A study of magnetic polishing for SUS304 with planetary bodies combined two-dimensional vibration. The main purpose of the planetary bodies of rotation and revolution characteristics, excellent surface morphology, and saving energy and time can also be reached. Series of experiments by controlling the working gap, the amplitude of the vibration platform, steel particle size and so on. This mechanism can enhance the surface quality and efficiency.
Taguchi experiment show that the combination of better parameters for the surface improvement : working gap 1 mm, the amplitude of the vibration platform 0.1mm, steel particle size of 0.125 mm , SiC weight of 3 g, steel weight of 0.5 g * 2, the weight of the slurry 5g, vibration platform frequency of 16.667Hz, magnet pole rotational speed 500 rpm (156).
For the curve improvement : working gap 0.5 mm, the amplitude of the vibration platform 0.1mm, steel particle size of 0.125 mm , SiC weight of 3 g, steel weight of 0.5 g * 2, the weight of the slurry 5g, vibration platform frequency of 16.667Hz, magnet pole rotational speed 500 rpm (156).
This mechanism can be effective in improving the stainless surface S.R. from Ra 0.23 μm to 0.058 μm, improvement rate was 74% and improving the stainless curve S.R. from Ra 0.23 μm to 0.058 μm, improvement rate was 74%. which can prove that planetary bodies combination of the two-dimensional vibration support mechanisms to improve quality.
Keywords: planetary bodies, two-dimensional vibration, polished stainless steel, rotation and revolution.

關鍵字(中)

★ 行星機構
★ 二維振動
★ 不鏽鋼拋光
★ 自轉與公轉

關鍵字(英)

★ planetary bodies
★ two-dimensional vibration
★ polished stainless steel
★ otation and revolution

論文目次

iv
目錄
摘要……………………………………………………………………………i
Abstract..............................................................................................................ii
謝誌..................................................................................................................iii
目錄..................................................................................................................iv
圖目錄......................................................................................................... viii
表目錄........................................................................................................... xi
第一章緒論......................................................................................................1
1-1 前言.....................................................................................................1
1-2 研究背景與目的.................................................................................4
1-3 研究架構.............................................................................................6
1-4 文獻回顧.............................................................................................7
第二章基本原理............................................................................................ 12
2-1 磁力研磨加工原理........................................................................... 12
2-2 磁性磨粒之切削加工機制............................................................... 15
2-3 PLC 可程式控制器原理............................................................... 17
2-4 伺服馬達與伺服驅動器.................................................................. 20
2-5 田口式品質工程.............................................................................. 23
2-5-1 田口方法概述...................................................................... 23 v
2-5-2 實驗設計流程...................................................................... 23
2-5-3 決定目標特性...................................................................... 25
2-5-4 直交陣列表.......................................................................... 25
2-5-5 訊號/噪音比......................................................................... 27
2-5-6 變異數分析.......................................................................... 27
2-5-7 驗證實驗.............................................................................. 29
第三章實驗設計與研究內容....................................................................... 30
3-1 實驗流程規劃.................................................................................. 30
3-2 加工構想.......................................................................................... 32
3-3 實驗材料.......................................................................................... 34
3-3-1 工件材料............................................................................... 34
3-3-2 磁性磨料............................................................................... 34
3-3-3 切削液................................................................................... 35
3-4 實驗設備.......................................................................................... 37
3-4-1 磁力輔助二維振動研磨機.................................................. 37
3-4-2 2D 表面粗度輪廓形狀量測機............................................ 38
3-4-3 3D 表面粗度輪廓形狀量測機............................................ 38
3-4-4 低真空掃描式電子顯微鏡（Low Vacuum-Scanning Electron
Microscope： LVSEM） ............................................................................ 39 vi
3-4-5 精密電子天平....................................................................... 40
3-4-6 超音波洗淨機....................................................................... 40
3-4-7 原子力顯微鏡(AFM)............................................................ 40
3-5 實驗方法........................................................................................ 41
3-5-1 實驗參數設計.................................. .................................. 41
3-5-2 實驗步驟............................................................................. 44
3-5-3 表面粗糙度之量測............................................................. 45
3-6 磁力輔助振動拋光設備................................................................. 46
3-6-1 振動輔助機構設計.............................................................. 46
3-6-2 磁極距離調整機構設計..................................................... .47
3-6-3 行星機構開發設計.............................................................. 48
3-6-4 PLC 控制程式撰寫.............................................................. 51
第四章結果與討論....................................................................................... 56
4-1 前置實驗.........................................................................................56
4-1-1 行星機構結合二維輔助振動機台穩定性分析................. 56
4-1-2 不同切削液對粗糙度之影響............................................. 57
4-1-3 實驗參數水準設計............................................................. 58
4-1-4 振動輔助對磁力研磨之影響............................................. 61
4-1-5 行星機構結合二維振動對磁力研磨之影響......................61
4-2 實驗結果分析................................................................................. 63
4-2-1 因子效果回應分析.............................................................. 63
4-2-2 變異數分析（ANOVA）及 F 檢定（F-test）.................. 66
4-2-3 驗證實驗............................................................................... 67
4-3 單因子實驗....................................................................................... 69
4-3-1 實驗條件與規劃................................................................... 69
4-3-2 磁極間距對表面粗糙度之影響........................................... 70
4-3-3 振動平台振福對表面粗糙度之影響................................... 73
4-3-4 鋼砂粒徑對表面粗糙度之影響.......................................... 76
4-3-5 SiC 重量對表面粗糙度之影響........................................ 79
4-3-6 鋼砂重量對表面粗糙度之影響.......................................... 82
4-3-7 研磨液重量對表面粗糙度之影響...................................... 85
4-3-8 振動平台頻率對表面粗糙度之影響.................................. 88
4-3-9 磁極轉速對表面粗糙度之影響.......................................... 91
4-4 行星機構優點之探討..................................................................... 94
第五章結論................................................................................................... 96
參考文獻......................................................................................................... 98

參考文獻

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指導教授

顏炳華(Piin-hwa Yan)

審核日期

2013-7-23

推文