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研究生： 林俊宏
Chun-Hung Lin
論文名稱： 多晶鑽石刀具刨削工具鋼之加工參數研究
Research on the Shaping Parameters of Tool Steel Using a Polycrystalline Diamond Tool
指導教授： 修芳仲
Fang-Jung Shiou
口試委員: 鄧昭瑞
Geo-Ry Tang
鍾俊輝
Chun-Hui Chung
學位類別： 碩士
Master
系所名稱： 工程學院 - 機械工程系
Department of Mechanical Engineering
論文出版年： 2012
畢業學年度： 100
語文別： 中文
論文頁數： 60
中文關鍵詞： 鑽石刀具 、鐵系金屬 、田口實驗 、表面粗糙度 、氮化處理
外文關鍵詞： diamond tool, ferrous metal, Taguchi experiment, surface roughness, nitriding treatment
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    • 有鑑於工業界在應用鑽石刀具切削鐵系金屬時，刀具會有快速磨耗導致粗糙度不佳，常需要將工件或是刀具經過特殊處理或鍍層才能進行加工，本研究主要為利用田口式L9直交表實驗法運用四種參數來進行加工實驗，以找出對SKD11表面粗糙度和刀具磨耗最小的最佳參數組合。
    依據實驗結果優化的參數組合為：調水油、10°C的加工溫度、5μm切削深度及鍍鎳處理。而本實驗為了尋找不同方法有利於鑽石刀具加工，特意利用工件氮化來取代鍍鎳處理。經驗證後的表面粗糙度約達到Ra 0.14μm。而鑽石刀具也在加工過170,000mm之後，依然是呈現無磨損的狀態，經過這次的實驗證明了，在ANOVA分析裡比重最重的氮化處理確實的是有它的功效存在的。

    According to the use of a polycrystalline diamond tool for cutting the ferrous metal in industry, the wearness rate was extremely high and resulted the surface roughness into worse. Some special treatments or coating should have been done on workpiece so that the diamond tool can be used to continue the cutting process. In this research, we conducted 4 parameters by using Taguchi L9 method to address the cutting process. These 4 parameters are surface treatment, cooling fluid, working temperature and depth of cut. Taguchi method is used to find the best combination for surface roughness and the minimum wearness on tool steel in this research.
    Based on the Taguchi L9 experiments, we can find the best parameters are as follow：surface treatment of nickel coating, cooling fluid of lubricant, working temperature of around 10°C and depth of cut of 0.005 mm. The machining of the workpiece of nickel coating using a diamond tool has already widely been used. After comparing the nitriding and nickel coating of test results, the difference is small. As a result, in this experiment we choose nitriding treatment instead of nickel coating to do the best combination experiment. The surface roughness of 0.14μm Ra was obtained by using the best combination parameters. By using the optical microscope to inspect the diamond tool after machining 170,000mm, it has almost no wearness. Through the experiments, we can prove that the nitriding treatment is effective for cutting the ferrous metal using a polycrystalline diamond tool.

    中文摘要...........................................................................................I Abstract………………………………………………………………….. II 誌謝…………………………………………………………….............. III 目錄................................................................................................IV 圖索引.................................................................................VII 表索引.........................................................................................IX 第一章 緒論.................................................................................... 1 1.1 研究動機及目的.................................................................1 1.2 文獻回顧............................................................................2 1.3 研究方法與論文架構........................................................4 第二章 田口式實驗計劃法............................................................6 2.1 前言...................................................................6 2.2因子的分類…………………………………………….6 2.2.1 信號因子.......................................7 2.2.2 雜音因子或干擾因子...........................7 2.2.3 可控因子………………………………………..8 2.3田口式實驗計劃法...........................................8 2.4 參數設計…..……………………………………..10 2.5 品質損失函數………..……………………………..13 2.6 訊號雜訊比………………………….…………………..16 2.7 變異數分析……………………………………………..18 2.8 F分佈……………………………….………………..21 2.9 直交表介紹………………………….………………..23 2.10最適條件下的最佳值預估與確認實驗………….……..25 第三章 實驗方法與步驟及數據分析..............................................27 3.1實驗方法........................................................27 3.1.1實驗系統流程圖.............................................27 3.2水準及因子的選用及L9直交表......................................28 3.3實驗加工設備及檢測設備...........................................31 3.3.1工件及鑽石刀具.............................................31 3.3.2加工設備及周邊設備....................................32 3.3.3表面粗糙度量測儀...........................................36 3.3.4 SKD11材料特性...........................................37 3.4田口法及ANOVA數據分析..........................................38 3.4.1田口實驗法................................................38 3.4.2加工驗證實驗.............................................43 3.4.3載具加工...............................................43 3.4.4刀具磨耗檢測.............................................45 第四章 結論與未來展望…………………………………………….48 4.1 結論…………………………………………………………48 4.2 未來展望……………………………………………………48 參考文獻……………………………………………………………...50 附錄…………………………………………………………………...53 作者簡介……………………………………………………………...59 圖 索 引 圖2.1 產品或製程方塊圖……....………………………..………..….8 圖2.2(a) 一階損失函數………………………………………..….13 圖2.2(b) 二次損失函數………………………………….……..…14 圖2.3 望目型品質特性圖…………………………………………...14 圖2.4 望大型品質特性圖………………………………………..….15 圖2.5 望小型品質特性圖………………………………………..….15 圖2.6 不對稱型品質特性圖..…………………………………….....15 圖2.7 F分佈曲線…………………………………………………...22 圖3.1 實驗系統流程圖………………………………..…………….28 圖3.2 加工實驗所用的工件…………………………………………31 圖3.3 鑽石刀具設計圖……………………………………..……….32 圖3.4 鑽石刀具實體圖……………………………………..……….32 圖3.5 DMC綜合切削加工中心機..………………………..……….33 圖3.6 氮氣產生機………………………………. ………….………34 圖3.7 加工過程……….…………………......................................34 圖3.8 光學顯微鏡檢測.…………………......................................35 圖3.9 表面粗糙度量測儀.………………......................................35 圖3.10 HOMMEELWERKE T4000型粗糙度量測儀......................36 圖3.11 加工方向及量測方向……………………….........................39 圖3.12 S/N Ratio折線圖…………………………….........................42 圖3.13平均反應折線圖……...……………………….......................42 圖3.14 透鏡模仁…………………………………….........................44 圖3.15透鏡模仁精加工……………………………………………....44 圖3.16透鏡模仁實體圖……...……………………….......................45 圖3.17磨耗檢測程式………...……………………….......................46 圖3.18鑽石刀具加工前照片...……………………….......................46 圖3.19鑽石刀具加工後照片……...………………………................47 表 索 引 表2.1 雜音因子………………………………………………..…….9 表2.2 變異數分析表……………………………………………….20 表2.3 L9(34)直交表………………………………………....…..….25 表3.1 水準及因子的選用……...…………………………………..29 表3.2 L9直交表…………………………………………………….30 表3.3 Measured Roughness to Cut-off.……...………………….37 表3.4 SKD11的化學成份………………………………………….38 表3.5 量測結果總表………………..………………..………..…...40 表3.6 ANOVA 變異數分析表……………………..………………41 表3.7 S/N Ratio 反應表………………………….………..………41 表3.8 平均值反應表………………..………………..………..…...42 表3.9 驗証實驗之表面粗糙度平均值與S/N比值………..………43

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