本研究中，為量測金屬玻璃鍍膜與碳纖維複合材料之磨潤行為，研發一創新銷對盤磨耗機構，搭載於數值控制工具機(computer numerical control, CNC)中，進行動力、溫度與電氣信號之同步量測。在四個觀測區間(I–Ⅳ:40 sec)中，透過信號擷取與分析，金屬玻璃鍍膜與碳纖維複合材料在磨耗試驗中之控制參數(金屬玻璃鍍膜0.25–2 μm、下壓力10–30 N與線速度50–100 m/min)與動態摩擦係數、電流值、磨耗溫度之擬合關係將可建立。並使用殘差分析解析交互作用與因子之貢獻度，演算系統之理論測試值及信賴區間，進而分離模型中之離群點(outliers)。當離群點被辨識且修正時，所建立之系統模型預測值與實驗之真實值趨近穩定(R2>85%)。之後，再建立包含金屬玻璃鍍膜所產生自潤滑效應之力學分析模型後，並以全因子實驗值(4×3×3)進行校驗，達到89.02%之分析模型精度。而分離離群點後，模型精度提升至90.23%。當抽離力學分析模型之關聯因子，進行控制參數對動摩擦係數與量測溫度之變異數分析(ANOVA)與顯著性檢定(significance)，顯示鍍膜厚度比線速度對摩擦係數更有顯著影響，其因子貢獻度(PCR)各為~43.2%與~25.9%。當鍍膜經歷磨耗與剝落後(interval Ⅳ)，摩擦係數與量測溫度之顯著控制參數轉變成線速度，其因子貢獻度(PCR)分別為~52.0%與~71.9%。在掃描式電子顯微鏡之表面觀測下，金屬玻璃鍍膜測試棒表面之磨耗特徵與碳纖維複合材料測試盤之破壞型式已完整建立，並詳盡討論。

This work presents a novel design of a Pin-on-Disc tribotesting system with retrofit applications in CNC machining centres to exhibit synchronised measurements of forces, temperatures, electrical signals. Based on the recorded measurements of coefficient of friction, electrical current and sliding temperature in a full factorial (4×3×3) experiment, normal load (10–30 N), sliding speed (50–100 m/min) and coated thin film metallic glass (TFMG: 0.25–2 μm) in the sliding pair with carbon fibre reinforced plastic (CFRP), residuals of the observations can be resolved and identified. With statistical analysis in the stochastic condition, parametric outliers interacting with system can be determined, as well as the model values and the associate the confident intervals to be identified. In the conditions of insulating or removing the outliers, the established Pin-on-Disc tribotesting system delivered with an appreciable precision level (R2 >85%) over 36 validation tests. Following the accuracy of the Pin-on-Disc tribotesting system being validated, influences of the operating parameters on the coefficient of friction, electrical current and sliding temperature would be consequently investigated. In the fit analytical models for the contact forces and grinding ratio, tribology effects of the TFMG coating were considered and initiated. When comparing the experimental results against the validated model values, a good agreement of the model accuracy (89.02%) to the experimental results was presented. In the evolution tests, the main effects and variances of the operating parameters on the observations were exanimated and discussed. Moreover, the preferable low coefficient of friction and sliding temperature could be obtained, with the significant factor of the coated thickness in PCR of 43.2% and 25.9% respectively. However, when the coating on the pins were worn and removed in the test interval Ⅳ (30–40 sec), the significant factor to the coefficient of friction and sliding temperature was diverted to sliding speed with PCR of ~52.0% and ~71.9% respectively. In the SEM observations of the microstructures on the worn TFMG coated pins and the CFRP discs, characterisations of the wear patterns and behaviour were reported and detailed with micrographs.

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